Sheet manufacturing apparatus

ABSTRACT

To manufacture sheets of uniform quality, a sheet manufacturing apparatus has a drum with a plurality of holes; a housing covering the drum; a conveyor on which material including fiber that has passed through the holes accumulates as a web, and which conveys the accumulated web; a first roller that is a first roller disposed to contact the web conveyed by the conveyor, and has asperities on its outside surface; and a first seal disposed to a first wall of the first housing to contact an outside surface of the first roller.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a U.S. National stage application of International Patent Application No. PCT/JP2016/084267, filed on Nov. 18, 2016, which claims priority under 35 U.S.C. § 119(a) to Japanese Patent Application No. 2015-231420, filed in Japan on Nov. 27, 2015, Japanese Patent Application No. 2015-231419, filed in Japan on Nov. 27, 2015, and Japanese Patent Application No. 2016-219432, filed in Japan on Nov. 10, 2016. The entire disclosures of Japanese Patent Application Nos. 2015-231420, 2015-231419, and 2016-219432 are hereby incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to a sheet manufacturing apparatus.

BACKGROUND

A sheet manufacturing apparatus having a housing, a pile seal connected to the housing, and a roller disposed in contact with the pile seal is known from the literature. (See, for example, JP-A-2015-120999.)

However, in the apparatus described above, material that sticks to the surface of the roller is scraped off by the pile seal and clumps, and the clumps then drop onto the deposited material, reducing the quality of the sheet.

In addition, material adhering to the surface of the roller is compressed by the load of the roller on the web, and then adheres to the surface of the roller.

Furthermore, if there is not a sufficient seal maintained between the suction device and mesh belt, material cannot be suctioned evenly inside the housing, and sheet quality drops.

SUMMARY

The present invention is directed to solving at least part of the foregoing problem, and can be achieved by the embodiments or examples described below.

EXAMPLE 1

A sheet manufacturing apparatus according to this example includes a drum with a plurality of holes; a first housing covering the drum; a conveyor on which material including fiber that has passed through the holes accumulates as a web, and which conveys the accumulated web; a first roller that is a first roller disposed to contact the web conveyed by the conveyor, and has asperities on an outside surface; and a first seal disposed to a first wall of the first housing to contact an outside surface of the first roller.

Thus comprised, material sticking to the surface of the first roller is more easily held by the asperities of the first roller, and more easily passes the first seal. Material remaining (accumulating) where the first roller and first seal touch is therefore more difficult, and production of clumps of material can be suppressed. In addition, sheets of consistent quality can be produced.

EXAMPLE 2

The asperities of a sheet manufacturing apparatus according to the above example are characterized by being disposed to the outside surface of the first roller in an area that contacts the web.

Thus comprised, clumping of material that falls onto the web is suppressed, and overall sheet quality can be improved.

EXAMPLE 3

The surface roughness of the outside surface of the first roller in the sheet manufacturing apparatus according to the above example is characterized by being greater than or equal to 30 μm and less than or equal to 500 nm.

Thus comprised, because the surface roughness of the first roller is greater than or equal to 30 μm and less than or equal to 500 μm, leaving material on the first roller is suppressed and an appropriate seal can be assured.

EXAMPLE 4

The first roller of the sheet manufacturing apparatus according to the above example is characterized by having a channel formed to a depth greater than or equal to 30 μm and less than or equal to 500 μm in the outside surface in a direction intersecting a direction of rotation of the first roller.

Thus comprised, leaving material on the first roller is suppressed and an appropriate seal can be assured as a result of forming a channel formed to a depth greater than or equal to 30 μm and less than or equal to 500 μm in the outside surface of the first roller.

EXAMPLE 5

The sheet manufacturing apparatus according to the above example characterized by the asperities of the first roller being formed in a screen pattern.

Thus comprised, material is entangled and held by the mesh, and producing clumps of material can be suppressed.

EXAMPLE 6

The first roller of the sheet manufacturing apparatus according to the above example is characterized by having a round recess with a depth greater than or equal to 30 μm and less than or equal to 500 μm, and a width greater than or equal to 0.1 mm and less than or equal to 2 mm, in the outside surface.

Thus comprised, because the outside surface of the first roller has round recesses, there are no burrs or sharp parts, and material catching and sticking on the outside surface of the first roller is suppressed. In addition, material sticking as a result of material (fiber or resin, for example) entering or sticking in the recesses is suppressed. As a result, adhering of material to the first roller can be suppressed, and sheets of consistent quality can therefore be produced.

EXAMPLE 7

The sheet manufacturing apparatus according to the above example characterized by having a removal device that contacts an outside surface of the first roller, and removes material stuck to the outside surface of the first roller.

Thus comprised, material sticking in the round recesses of the first roller is scraped out by the removal device. As a result, adhering of material to the first roller can be suppressed.

EXAMPLE 8

The first seal of the sheet manufacturing apparatus according to the above example is characterized by contacting the outside surface of the first roller at an angle of greater than or equal to 45 degrees and less than or equal to 90 degrees to a virtual vertical plane tangent to the outside surface of the first roller.

Thus comprised, because the first seal contacts the first roller at a diagonal position, material sticking to the first roller can easily pass the first seal, and material accumulating at the seal is made more difficult.

EXAMPLE 9

The sheet manufacturing apparatus according to the above example, characterized by having a second roller positioned on upstream in the conveyance direction of the web from the first roller; and a second seal disposed to a second wall opposite a first wall of the first housing and contacting the second roller; the second roller having asperities on its outside surface.

Thus comprised, material sticking to the outside surface of the second roller on the upstream side in the conveyance direction of the web is also conveyed in the direction of rotation of the second roller and it is therefore more difficult for the material to remain (accumulate) at the second seal. Clumping of material around the second seal can therefore be suppressed.

EXAMPLE 10

The sheet manufacturing apparatus according to the above example, characterized by the conveyor having a mesh member that conveys the web; and the sheet manufacturing apparatus including a suction device configured to suction material including fiber onto the mesh member, and having a second housing defining the suction area; a third roller that is a third roller disposed to a position opposite the first roller with the mesh member therebetween, and has asperities on its outside surface; and a third seal disposed to the second housing to contact an outside surface of the third roller.

Thus comprised, material sticking to the outside surface of the third roller in the area around the suction device is conveyed in the direction of rotation of the third roller and it is therefore more difficult for the material to remain (accumulate) at the third seal. Clumping of material around the third seal can therefore be suppressed.

EXAMPLE 11

A sheet manufacturing apparatus according to this example has a drum with a plurality of holes; a housing covering the drum; a conveyor on which material including fiber that has passed through the holes accumulates as a web, and which conveys the accumulated web; a first roller that contacts a web conveyed by the conveyor; and a first seal that is a first seal disposed to a first wall of the housing to contact an outside surface of the first roller, and contacts the outside surface of the first roller at an angle of greater than or equal to 45 degrees and less than or equal to 90 degrees to a virtual vertical plane tangent to the outside surface of the first roller.

Thus comprised, because the first seal contacts the first roller at a diagonal position, material sticking to the first roller can easily pass the first seal, and material accumulating at the seal is made more difficult.

EXAMPLE 12

A sheet manufacturing apparatus according to this example has a drum with a plurality of holes; a first housing covering the drum; a conveyor on which material including fiber that has passed through the holes accumulates as a web, and which conveys the accumulated web; and a first roller that contacts the web conveyed by the conveyor, and has round recesses in its outside surface.

Thus comprised, because the outside surface of the first roller has round recesses, material catching and sticking on the outside surface of the first roller is suppressed, and adhering of material to the first roller can be suppressed. Sheets of consistent quality can therefore be produced.

EXAMPLE 13

The recess of the sheet manufacturing apparatus according to example 12 is characterized by being disposed in the area of the outside surface of the first roller that contacts the web.

Thus comprised, material sticking to the outside surface of the first roller can be effectively suppressed.

EXAMPLE 14

The recess of the sheet manufacturing apparatus according to example 12 or 13 are characterized by having a depth greater than or equal to 30 μm and less than or equal to 500 μm, and a width greater than or equal to 0.1 ma and less than or equal to 2 am.

Thus comprised, there are no burrs or sharp parts on the outside surface of the first roller, and material catching and sticking can be suppressed. In addition, material sticking material (fiber or resin, for example) entering or sticking in the recesses is suppressed, and adhering of material to the first roller can be suppressed.

EXAMPLE 15

In a sheet manufacturing apparatus according to example 12 to 14, surface processing to improve the wear resistance is applied to the outside surface of the first roller.

Thus comprised, because wear of the outside surface of the first roller is suppressed, adhering of material to the first roller can be suppressed for a long time, and sheets of consistent quality can be produced.

EXAMPLE 16

In a sheet manufacturing apparatus according to example 12 to 15, surface processing to reduce surface free energy is applied to the outside surface of the first roller.

Thus comprised, the surface free energy of the outside surface of the first roller is reduced, and sticking of material to the first roller can be suppressed.

EXAMPLE 17

The sheet manufacturing apparatus according to example 12 to 16, characterized by also having a removal device that contacts the outside surface of the first roller and removes the material sticking to the outside surface of the first roller.

Thus comprised, material sticking in the recesses of the first roller is scraped out by the removal device. As a result, adhering of material to the first roller can be reliably suppressed.

EXAMPLE 18

The sheet manufacturing apparatus according to example 12 to 17, characterized by also having a first seal that contacts an outside surface of the first roller and is disposed to a first wall of the housing.

Thus comprised, the first roller and first seal can improve the seal of the first housing. In addition, the round recesses in the first roller also have a retention function of holding material sticking in the recesses. As a result, material sticking in the round recesses of the first roller easily pass the first seal. Material remaining (accumulating) where the first roller and first seal touch is therefore made more difficult, and production of clumps of material can be suppressed. In addition, adhering of material to the first roller can be suppressed.

EXAMPLE 19

The sheet manufacturing apparatus according to example 12 to 18, characterized by also having a second roller positioned on upstream in the conveyance direction of the web from the first roller; and a second seal that contacts the second roller and is disposed to a second wall opposite the first wall of the housing; the second roller having a round recess on its outside surface.

Thus comprised, material catching and sticking to the outside surface of the second roller on the upstream side in the conveyance direction of the web is reduced, and adhering of material to the second roller can be suppressed.

EXAMPLE 20

The sheet manufacturing apparatus according to example 12 to 19, characterized by the conveyor having a mesh member that conveys the web; the sheet manufacturing apparatus also having a suction device including a configured to suction material including fiber onto the mesh member, and having a second housing defining the suction area; a third roller that is a third roller disposed to a position opposite the first roller with the mesh member therebetween, and has round recesses on its outside surface; and a third seal that contacts an outside surface of the third roller, and is disposed to the second housing.

Thus comprised, material catching and sticking to the outside surface of the third roller is reduced in the area around the suction device, and adhering of material to the third roller can be suppressed.

EXAMPLE 21

A sheet manufacturing apparatus according to this variation is characterized by having a drum with a plurality of holes; a mesh member having an accumulation surface on which material including fiber that has passed through the openings accumulates as a web, the mesh member conveying the accumulated web; a suction device that is a suction device configured to suction material that has passed through the openings onto the mesh member, and having on the back side of the accumulation surface of the mesh member a first housing defining the suction area; a first roller disposed outside the first housing and contacting the back side of the mesh member; and a first seal disposed to the first housing and contacting the outside surface of the first roller.

Thus comprised, the space enclosed by the first roller, first housing, and mesh member is substantially closed tight (sealed) by the first seal and the first roller. As a result, suction from between the first roller and first housing is suppressed, and material that has passed through the holes in the drum can be consistently suctioned. As a result, sheets with even greater uniformity can be produced.

EXAMPLE 22

The first seal of the sheet manufacturing apparatus according to example 21 is characterized by being disposed with at least part thereof not in contact with the back of the mesh member.

Thus comprised, because in the area where the mesh member and first seal are separated material does not stick and get clogged in the gap between the mesh member and the first seal, the load on the mesh member can be suppressed.

EXAMPLE 23

The first seal of the sheet manufacturing apparatus according to example 22 is characterized by being disposed contacting the back of the mesh member outside the suction area, and in contact with the end of the first roller.

Thus comprised, because the load on the mesh member is suppressed, suction from between the first housing and the mesh member can be more reliably suppressed.

EXAMPLE 24

The first seal of the sheet manufacturing apparatus according to example 22 is characterized by being disposed contacting the back of the mesh member outside an area extending the suction area in the conveyance direction of the web, and in contact with the outside surface of the first roller.

Thus comprised, because the load on the mesh member is suppressed, suction from between the first housing and the mesh member can be more reliably suppressed.

EXAMPLE 25

The first seal of a sheet manufacturing apparatus according to example 21 to 24, characterized by having a second roller disposed outside the first housing on the upstream side in the conveyance direction of the web from the first roller and, in contact with the mesh member; and a second seal disposed to the first housing in contact with the outside surface of the second roller.

Thus comprised, the space enclosed second roller, first housing, and mesh member on the upstream side in the conveyance direction of the web is substantially closed tight (sealed) by the second seal and second roller. As a result, suction from between the first roller and first housing is suppressed, and material that has passed through the holes in the drum can be consistently suctioned. As a result, sheets with even greater uniformity can be produced.

EXAMPLE 26

The first seal of a sheet manufacturing apparatus according to example 21 to 25, characterized by having a second housing that covers the drum.

Thus comprised, material that has passed through the holes in the drum inside the second housing can be more consistently deposited on the accumulation surface of the mesh member.

EXAMPLE 27

The first seal of a sheet manufacturing apparatus according to example 21 to 25, characterized by having a third roller that contacts the web conveyed by the mesh member; and a third seal that contacts the outside surface of the third roller and is disposed to the second housing covering the drum; the first roller and the third roller being disposed at opposing positions with the mesh member therebetween.

Thus comprised, because the first roller and third roller oppose each other with the mesh member therebetween, the mesh member does not separate from the first roller, and a more reliable seal can be assured.

EXAMPLE 28

The first seal of a sheet manufacturing apparatus according to example 23 or 24, characterized by having second housing that covers the drum; the second housing including a first wall and a second wall opposite each other in the direction of the axis of rotation of the drum, a fourth seal disposed to the first wall and contacting the accumulation surface of the mesh member, and a fifth seal disposed to the second wall and contacting the accumulation surface of the mesh member; the fourth seal and the fifth seal characterized by at least a part thereof opposite the first seal with the mesh member therebetween.

Thus comprised, because part of the fourth seal and the fifth seal are disposed oppose each other, a reliable seal can be assured between the mesh member and the first wall and second wall of the second housing.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 schematically illustrates the configuration of a sheet manufacturing apparatus according to a first embodiment of the invention.

FIG. 2A is a schematic section view illustrating the configuration of an air-laying device according to a first embodiment of the invention.

FIG. 2B is an oblique view illustrating the configuration of an air-laying device according to a first embodiment of the invention.

FIG. 3A is an external view illustrating the configuration of a first roller according to a first embodiment of the invention.

FIG. 3B is a partial section view illustrating the configuration of a first roller according to a first embodiment of the invention.

FIG. 4A schematically illustrates contact between a first seal and first roller according to a first embodiment of the invention.

FIG. 4B schematically illustrates contact between a first seal and first roller according to a first embodiment of the invention.

FIG. 5A schematically illustrates operation around a first roller in a first embodiment of the invention.

FIG. 5B schematically illustrates operation around a second roller in a first embodiment of the invention.

FIG. 6A is an external view illustrating the configuration of a first roller according to a second embodiment of the invention.

FIG. 6B is a partial section view illustrating the configuration of a first roller according to a second embodiment of the invention.

FIG. 6C is an external view illustrating the configuration of another first roller according to a second embodiment of the invention.

FIG. 7A is an external view illustrating the configuration of a first roller according to a third embodiment of the invention.

FIG. 7B is a partial section view illustrating the configuration of a first roller according to a third embodiment of the invention.

FIG. 8 schematically illustrates the configuration of a wetting device according to a fourth embodiment of the invention.

FIG. 9 schematically illustrates the configuration of a classifier according to a fifth embodiment of the invention.

FIG. 10A schematically illustrates contact between a first seal and first roller according to a sixth embodiment of the invention.

FIG. 10B schematically illustrates contact between a first seal and first roller according to a sixth embodiment of the invention.

FIG. 11A schematically illustrates the configuration of an air-laying device according to a seventh embodiment of the invention.

FIG. 11B is an oblique view of part of the air-laying device according to a seventh embodiment of the invention.

FIG. 12A is an external view illustrating the configuration of a first roller according to a seventh embodiment of the invention.

FIG. 12B is a partial section view illustrating the configuration of a first roller according to a seventh embodiment of the invention.

FIG. 13A schematically illustrates contact between a first seal and first roller according to a seventh embodiment of the invention.

FIG. 13B schematically illustrates contact between a first seal and first roller according to a seventh embodiment of the invention.

FIG. 14A schematically illustrates operation around a first roller in a seventh embodiment of the invention.

FIG. 14B schematically illustrates operation around a third roller in a first embodiment of the invention.

FIG. 15A schematically illustrates the configuration of an air-laying device according to an eighth embodiment of the invention.

FIG. 15B schematically illustrates operation around a first roller in an eighth embodiment of the invention.

FIG. 15C schematically illustrates operation around a third roller in an eighth embodiment of the invention.

FIG. 16 is an external view illustrating the configuration around a first roller in a ninth embodiment of the invention.

FIG. 17A is a section view schematically illustrating the configuration around the suction device of the air-laying device according to a tenth embodiment of the invention.

FIG. 17B is a plan view illustrating the configuration around the suction device of the air-laying device according to a tenth embodiment of the invention.

FIG. 17C is an oblique view illustrating part of the configuration around the suction device of the air-laying device according to a tenth embodiment of the invention.

FIG. 18 is an oblique view illustrating part of the configuration around the air-laying device according to a tenth embodiment of the invention.

FIG. 19 is an oblique view illustrating part of the configuration around the suction device of the air-laying device according to an eleventh embodiment of the invention.

FIG. 20 schematically illustrates the configuration around the suction device of a wetting device according to a twelfth embodiment of the invention.

FIG. 21 schematically illustrates the configuration around the suction device of a classifier according to a thirteenth embodiment of the invention.

FIG. 22 is a partial oblique view illustrating the configuration of a first seal according to a variation of the invention.

DESCRIPTION OF EMBODIMENTS

A preferred embodiment of the invention is described below with reference to the accompanying figures. Note that parts are shown in the accompanying figures in sizes enabling easy recognition thereof, and differ from the actual scale of the actual parts.

Embodiment 1

A sheet manufacturing apparatus according to a first embodiment of the invention is described first. FIG. 1 schematically illustrates the configuration of a sheet manufacturing apparatus according to this embodiment of the invention.

As shown in FIG. 1, the sheet manufacturing apparatus 100 includes a supply device 10, manufacturing device 102, and controller 104. The manufacturing device 102 manufactures sheets. The manufacturing device 102 includes a shredder 12, defibrator 20, classifier 40, first web forming device 45, rotor 49, mixing device 50, air-laying device 60, second web forming device 70, sheet forming device 80, cutting device 90, and discharge device 96.

The supply device 10 supplies feedstock to the shredder 12. The supply device 10 is, for example, an automatic loader for continuously supplying feedstock material to the shredder 12. The feedstock supplied by the supply device 10 includes fiber from recovered paper or pulp sheets, for example.

The shredder 12 cuts feedstock supplied by the supply device 10 into shreds in air. The shreds in this example are pieces a few centimeters square. In the example in the figure, the shredder 12 has shredder blades 14, and can shred the supplied feedstock by the shredder blades 14. In this example, a paper shredder is used as the shredder 12. The feedstock shredded by the shredder 12 is received into a hopper 1 and carried (conveyed) to the defibrator 20 through a conduit 2.

The defibrator 20 defibrates the feedstock shredded by the shredder 12. Defibrate as used here is a process of separating feedstock (material to be defibrated) comprising many interlocked fibers into individual detangled fibers. The defibrator 20 also functions to separate particulate such as resin, ink, toner, and sizing agents in the feedstock from the fibers.

Material that has passed through the defibrator 20 is referred to as defibrated material. In addition to untangled fibers, the defibrated material may also contain resin particles (resin used to bind multiple fibers together), coloring agents such as ink and toner, sizing agents, paper strengthening agents, and other additives that are separated from the fibers when the fibers are detangled. The shape of the detangleddefibratedmaterial is a string or ribbon. The detangled defibrated material may be separated from (not interlocked with) other detangled fibers, or may be in lumps interlocked with other detangled defibrated material (in so-called fiber clumps).

The defibrator 20 defibrates in a dry process. Processes including defibrating that are performed in ambient air (air) instead of a liquid are referred to herein as dry processes. In this embodiment, an impeller mill is used as the defibrator 20. The defibrator 20 also has the function of creating an air flow that sucks in the feedstock and then discharges the defibrated material. As a result, the defibrator 20 can suction the feedstock with the air flow from the inlet 22, defibrate, and then convey the defibrated material to the exit 24 using the air flow produced by the defibrator 20. The defibrated material that has passed through the defibrator 20 is conveyed through a conduit 3 to the classifier 40. Note that the air stream conveying the defibrated material from the defibrator 20 to the classifier 40 may be the air current created by the defibrator 20, or a separate blower or other fan device may be used to create the air current.

The classifier 40 selects fibers by length from the defibrated material defibrated by the defibrator 20 that was introduced through an inlet 42. A sieve (sifter) (drum) 41, for example, is used as the classifier 40. The sieve (drum) 41 of the classifier 40 has mesh (filter, screen), and can separate fiber or particles that are smaller than the size of the openings in the mesh (that pass through the mesh, first selected material) from fiber, undefibrated shreds, and clumps that are larger than the openings in the mesh (that do not pass through the mesh, second selected material). For example, the first selected material is conveyed to a first web forming device 45. The second selected material is returned from an outlet 44 through a conduit 8 to the defibrator 20.

More specifically, the sieve (drum) 41 of the classifier 40 is a cylinder driven rotationally by a motor. The mesh of the classifier 40 may be a metal screen, expanded metal made by expanding a metal sheet with slits formed therein, or punched metal having holes formed by a press in a metal sheet, for example.

The first web forming device 45 conveys the first selected material from the classifier 40 through a conduit 7 to the mixing device 50. The first web forming device 45 includes, for example, a mesh belt 46, tension rollers 47, and a suction device (suction mechanism) 48.

The suction device 48 suctions the first selected material that has passed through the openings (mesh openings) in the classifier 40 and was dispersed in air onto the mesh belt 46. The first selected material accumulates on the moving mesh belt 46, forming a web V. The basic configuration of the mesh belt 46, tension rollers 47, and suction device 48 are the same as the mesh belt 72, tension rollers 74, and suction mechanism 76 (suction device) of the second web forming device 70 described below.

The web V is a soft, fluffy web containing a lot of air as a result of passing through the classifier 40 and first web forming device 45. The web V deposited on the mesh belt 46 is fed into a conduit 7 and conveyed to the mixing device 50.

The rotor 49 can cut the web V before the web V is conveyed to the mixing device 50. In the example in the figure, the rotor 49 has a base 49 a, and blades 49 b protruding from the base 49 a. The blades 49 b in this example have a flat shape. In the example in the figure, there are four blades 49 b, and the four blades 49 b are equally spaced around the base 49 a. By the base 49 a turning in direction R, the blades 49 b rotate on the axis of the base 49 a. By cutting the web V with the rotor 49, variation in the amount of defibrated material per unit time supplied to the air-laying device 60, for example, can be reduced.

The rotor 49 is disposed near the first web forming device 45. In the example in the figure, the rotor 49 is disposed near a tension roller 47 a (beside the tension roller 47 a) located at the downstream side of the conveyance path of the web V. The rotor 49 is disposed at a position where the blades 49 b can contact the web V but do not touch the mesh belt 46 on which the web V is laid. As a result, wear (damage) to the mesh belt 46 by the blades 49 b can be suppressed. The minimum distance between the blades 49 b and mesh belt 46 is preferably greater than or equal to 0.05 mm and less than or equal to 0.5 mm. for example. This is a distance enabling cutting the web V without the mesh belt 46 being damaged.

The mixing device 50 mixes an additive containing resin with the first selected material (the first selected material conveyed by the first web forming device 45) that has passed through the classifier 40. The mixing device 50 has an additive supply device 52 that supplies additive, a conduit 54 for conveying the selected material and additive, and a blower 56. In the example in the figure, the additive is supplied from the additive supply device 52 through a hopper 9 to a conduit 54. Conduit 54 communicates with conduit 7.

The mixing device 50 uses the blower 56 to produce an air flow, and can convey while mixing the selected material and additives in the conduit 54. Note that the mechanism for mixing the first selected material and additive is not specifically limited, and may mix by means of blades turning at high speed, or may use rotation of the container like a V blender.

A screw feeder such as shown in FIG. 1, or a disc feeder not shown, for example, may be used as the additive supply device 52. The additive supplied from the additive supply device 52 contains resin for binding multiple fibers together. The multiple fibers are not bonded together at the time the resin is supplied. The resin melts and binds multiple fibers when passing the sheet forming device 80.

The resin supplied from the additive supply device 52 is a thermoplastic resin or thermoset resin, such as AS resin, ABS resin, polypropylene, polyethylene, polyvinyl chloride, polystyrene, acrylic resin, polyester resin, polyethylene terephthalate, polyethylene ether, polyphenylene ether, polybutylene terephthalate, nylon, polyimide, polycarbonate, polyacetal, polyphenylene sulfide, and polyether ether ketone. These resins may be used individually or in a desirable combination. The additive supplied from the additive supply device 52 may be fibrous or powder.

In addition to resin for binding fibers, and depending on the type of sheet being manufactured, the additive supplied from the additive supply device 52 may also include a coloring agent for coloring the fiber, an anti-blocking agent to prevent agglomeration of fibers and agglomeration of resin, or a flame retardant for making the fiber difficult to burn. The mixture (a mixture of first selected material and additive) that has passed through the mixing device 50 is conveyed through a conduit 54 to the air-laying device 60.

The mixture that has passed through the mixing device 50 is introduced from an inlet 62 to the air-laying device 60, and the air-laying device 60 detangles and disperses the tangled defibrated material (fiber) in air while the mixture precipitates. When the resin in the additive supplied from the additive supply device 52 is fibrous, the air-laying device 60 also detangles interlocked resin fibers. As a result, the air-laying device 60 can lay the mixture uniformly in the second web forming device 70.

A cylindrical sieve (drum 61) that turns is used as the air-laying device 60. The sieve (drum 61) of the air-laying device 60 has mesh, and causes fiber and particles smaller than the size of the mesh (that pass through the mesh) and contained in the mixture that has passed through the mixing device 50 to precipitate. The configuration of the air-laying device 60 in this example is the same as the configuration of the classifier 40.

Note that the sieve of the air-laying device 60 may be configured without functionality for selecting specific material. More specifically, the sieve used as the air-laying device 60 means a device having mesh, and the air-laying device 60 may cause all of the mixture introduced to the air-laying device 60 to precipitate.

The second web forming device 70 lays the precipitate that has passed through the air-laying device 60 into a web w. The web forming device 70 includes, for example, a mesh belt 72, tension rollers 74, and a suction mechanism 76 as a suction device.

The mesh belt 72 is moving while precipitate that has passed through the holes (holes of the mesh) of the air-laying device 60 accumulates thereon. The mesh belt 72 is tensioned by the tension rollers 74, and is configured so that air passes through but it is difficult for the precipitate to pass through. The mesh belt 72 moves when the tension rollers 74 turn. A web W is formed on the mesh belt 72 as a result of the mixture that has passed through the air-laying device 60 precipitating continuously while the mesh belt 72 moves continuously. The mesh belt 72 may be metal, plastic, cloth, or nonwoven cloth.

The suction mechanism 76 is disposed below the mesh belt 72 (on the opposite side as the air-laying device 60). The suction mechanism 76 produces a downward flow of air (air flow directed from the air-laying device 60 to the mesh belt 72). The mixture distributed in air by the air-laying device 60 can be pulled onto the mesh belt 72 by the suction mechanism 76. As a result, the discharge rate from the air-laying device 60 can be increased. A downward air flow can also be created in the descent path of the mixture, and interlocking of defibrated material and additive during descent can be prevented, by the suction mechanism 76.

A soft, fluffy web W containing much air is formed by material passing through the air-laying device 60 and second web forming device 70 (web forming process) as described above. The web W laid on the mesh belt 72 is then conveyed to the sheet forming device 80.

Note that a wetting device 78 for adjusting the moisture content of the web W is disposed in the example shown in the figure. The wetting device 78 adds water or water vapor to the web W to adjust the ratio of water to web W.

The sheet forming device 80 applies heat and pressure to the web W laid on the mesh belt 72, forming a sheet 8. By applying heat to the web W (a mixture of defibrated material and additive), the sheet forming device 80 can bind fibers in the web W together through the additive (resin).

The sheet forming device 80 includes a compression device 82 that compresses the web W, and a heating device 84 that heats the web W after being compressed by the compression device 82. The compression device 82 in this example comprises a pair of calender rolls 85 that apply pressure to the web W. Calendering reduces the thickness of the web w and increases the density of the web W. A heat roller (heating roller), hot press molding machine, hot plate, hot air blower, infrared heater, or flash fuser, for example, may be used as the heating device 84. In the example in the figure, the heating device 84 comprises a pair of heat rollers 86. By configuring the heating device 84 with heat rollers 86, a sheet 8 can be formed while continuously conveying the web W, unlike when the heating device 84 is configured with a flat press (flat press machine). The calender rolls 85 (compression device 82) can apply greater pressure to the web W than the pressure that can be applied by the heat rollers 86 (heating device 84). Note that the number of calender rolls 85 and heat rollers 86 is not specifically limited.

The cutting device 90 cuts the sheet S formed by the sheet forming device 80. In the example in the figure, the cutting device 90 has a first cutter 92 that cuts the sheet 8 crosswise to the conveyance direction of the sheet S, and a second cutter 94 that cuts the sheet S parallel to the conveyance direction. In this example, the second cutter 94 cuts the sheet 8 after passing through the first cutter 92.

Cut sheets B of a specific size are formed by the process described above. The cut sheets S are then discharged to the discharge device 96.

The detailed configuration of the air-laying device is described next. FIG. 2A is a schematic section view illustrating the configuration of the air-laying device, and FIG. 2B is an oblique view illustrating the configuration of the air-laying device. FIG. 3A is an external view illustrating the configuration of a first roller, and FIG. 3B is a partial section view illustrating the configuration of the first roller. FIG. 4A and FIG. 4B schematically illustrate contact between a first seal and first roller. Note that in FIG. 2A the configuration is shown without the wetting device.

As shown in FIG. 2A, the air-laying device 60 includes a foraminous drum 61 (sieve); a first housing 600 covering the drum 61; a conveyor 700 on which material (precipitate) including fiber that has passed through the holes in the drum 61 accumulates as a web W, and which conveys the deposited web W; a first roller 650 that contacts the web W conveyed by the conveyor 700, and has a textured outside surface; and a first seal 610 disposed to a first wall 600 a of the first housing 600 and touching the outside surface of the first roller 650.

The drum 61 includes a rotatable cylinder, and numerous holes through which at least material including fiber carried by air passes are formed in the cylinder. The many holes are the same size (area) and are disposed at a uniform spacing. When passing through the holes, tangled fibers are detangled, and the material passing through the holes accumulates at a uniform thickness and density on the mesh belt 72. Note that the size of the holes is set desirably according to the size and type of the material that is past. In addition, the holes are not limited to holes formed in punched metal, and may be a metal screen.

The first housing 600 has a frame 601, and is hollow inside. The drum 61 is placed inside the frame 601, and is thereby covered (surrounded) by the first housing 600. The bottom of the first housing 600 does not have a floor panel, and is open.

The conveyor 700 accumulates material including fiber that has passed through the holes in the drum 61 as a web W, and conveys the accumulated web W. The conveyor 700 in this embodiment of the invention is part of the second web forming device 70, and more specifically includes a mesh belt 72 and tension rollers 74. The configuration of the mesh belt 72 and tension rollers 74 is as described above and further description thereof is omitted.

On the downstream side of the first housing 600 in the conveyance direction of the web w is disposed a first roller 650 that contacts the web W conveyed by the mesh belt 72. Disposed to the first wall 600 a of the first housing 600 is a first seal 610, which contacts the outside surface of the first roller 650. The first wall 600 a has an outside surface, an inside surface, and an end (the surface facing the mesh belt 72). Note that the first seal 610 in this embodiment of the invention is disposed to the outside surface of the first wall 600 a. The first seal 610 and first roller 650 are in contact with each other.

As shown in FIG. 2B, the first roller 650 is disposed with its axis of rotation in the direction transverse to the conveyance direction of the web W (widthwise to the web W). The length of the first roller 650 is the same as the width of the frame 601 of the first housing 600 (the width of the web W).

The first roller 650 is connected to a drive device (not shown in the figure) such as a motor that drives the first roller 650. By driving the drive device, the first roller 650 can be turned on its axis of rotation (counterclockwise in FIG. 2A). The drive speed (circumferential speed) of the first roller 650 is set to be faster than the conveyance speed (speed of travel) of the web W by the mesh belt 72. In other words, the first roller 650 is configured so that the circumferential speed is greater than the conveyance speed (speed of travel) of the web W by the mesh belt 72. As a result, the web W can be pulled more easily in the conveyance direction, accumulation of the web W and buckling of the web W inside the first housing 600 are reduced, and the web W can be conveyed stably.

The first roller 650 is disposed so that its axis of rotation is positioned above the maximum height (thickness) of the web W that accumulates upstream in the conveyance direction from the first roller 650. If the axis of rotation of the first roller 650 is at a position lower than the maximum height (thickness) of the web W that accumulates upstream in the conveyance direction from the first roller 650, conveying the top part of the accumulated web W becomes difficult, and the web W can easily accumulate inside the first housing 600.

The first roller 650 can move vertically (perpendicularly to the accumulation surface of the mesh belt 72, or the thickness of the web W), and is urged down (to the mesh belt 72 side) by an urging member (not shown in the figure).

Asperities Nf are disposed to the outside surface F of the first roller 650. The asperities Nf are formed in the area of the outside surface F of the first roller 650 that contacts the web W. As shown in FIG. 3A, in this embodiment of the invention the asperities Nf are formed over the entire outside surface F of the first roller 650.

As shown in FIG. 3B, in this embodiment of the invention the asperities Nf are formed by processing the outside surface F of the first roller 650 to a surface roughness of greater than or equal to 30 μm and less than or equal to 500 μm. The first roller 650 is a metal roller made from an aluminum alloy or stainless steel, for example, and the asperities Nf are formed by a mechanical or chemical satinizing process (such as a spray coating process or sandblasting process) that roughens the surface.

The surface roughness used herein is expressed by the mean height of profile elements Rc (JIS B 0601) as defined based on JIS B 0601 (2001) or ISO 4287 (1997). The surface roughness is measured according the foregoing standard, and as the measurement means a device that measures surface roughness while in contact with the test surface (such as a contact-type surface roughness tester) or a device that measures without contacting the test surface (such as a white light interferometer or laser scanning microscope).

The asperities Nf (a surface roughness greater than or equal to 30 μm and less than or equal to 500 μm) of the outside surface F of the first roller 650 make it difficult for material including fiber to remain (accumulate) on the first seal 610 when material including fiber adhering to the first roller 650 is conveyed in the direction of rotation of the first roller 650. If the surface roughness is less than 30 μm, the effect of inhibiting material remaining (accumulating) on the first seal 610 is reduced. If the surface roughness exceeds 500 μm, the gap between concavities in the first roller 650 and the first seal 610 increase, and the seal effect may drop. In addition, the pattern of the asperities Nf may be transferred to the web W due to the size (depth) of the asperities on the surface of the roller, and the quality of the sheet may drop.

The first seal 610 in this example is a pile seal comprising a base FL and numerous fibers H planted densely on the one side of the base FL (see FIG. 4A). The other side of the base FL of the first seal 610 is attached to the outside surface of the first wall 600 a of the first housing 600, and the distal ends of the fibers H of the first seal 610 are configured to touch the outside surface F of the first roller 650.

More specifically, as shown in FIG. 4A, for example, the first seal 610 is disposed so that the angle θ1 of the first seal 610 to a virtual vertical plane SP to the outside surface F of the first roller 650 is 90 degrees. More specifically, the first seal 610 and first roller 650 are disposed so that the distal ends of the fibers H in the first seal 610 are substantially perpendicular to the virtual vertical plane SP. Note that the distal ends of the fibers H in the first seal 610 are pushed against the outside surface F of the first roller 650. As a result, the gap between the outside surface of the first wall 600 a of the first housing 600 and the first roller 650 is substantially closed by the first seal 610. In addition, when the first roller 650 and the first seal 610 slide against each other as the first roller 650 turns, wear and friction are suppressed compared with when a foam sponge is used as the first seal 610, and the drive load on the first roller 650 can be reduced. The length of the fibers of the first seal 610 is set so that the first seal 610 reliably contacts the first roller 650. For example, the length is set longer than the width of the gap between the first wall 600 a of the first housing 600 and the first roller 650.

Note that in FIG. 4A the angle θ1 of the first seal 610 is set to 90 degrees, but the invention is not limited to this configuration. The first seal 610 may be set to contact the outside surface F of the first roller 650 at an angle greater than or equal to 45 degrees and less than or equal to 90 degrees to the virtual vertical plane SP tangent to the outside surface F of the first roller 650.

As shown in FIG. 4B, for example, the first seal 610 may be disposed to contact the outside surface F of the first roller 650 at an angle 81 of 45 degrees to the virtual vertical plane SP tangent to the outside surface F of the first roller 650. If the angle 81 is within the foregoing range, a good seal can be assured between the first seal 610 and first roller 650.

Operation in the area around the first roller is described next. FIG. 5A schematically illustrates operation in the area around the first roller. When driving the sheet manufacturing apparatus 100, material including fiber from the opening in the drum 61 accumulates on the mesh belt 72. The accumulated material (web W) is conveyed by movement of the mesh belt 72. At this time, the first roller 650 also turns in contact with the web w (counterclockwise in FIG. 2A and FIG. 5A). Material forming the web W may also stick to the outside surface F of the first roller 650 at this time. In this event, the material sticking to the outside surface F is held by the asperities Nf formed on the outside surface F of the first roller 650 and moves rotationally in conjunction with rotation of the first roller 650. In addition, in the area where the first seal 610 and first roller 650 touch, the distal ends of the fibers H of the first seal 610 curve in the direction of rotation of the first roller 650 due to friction with the asperities Nf of the first roller 650 (the distal ends of the fibers H bend down in FIG. 5A). As a result, the material clinging to the first roller 650 is easily conveyed in the direction the distal ends of the fibers H of the first seal 610 bend. The material clinging to the first roller 650 is held by the asperities Nf, and passes through the area of contact between the first seal 610 and first roller 650 without being wiped of f by the first seal 610. As a result, material clumping (agglomerating) near the area of contact between the first seal 610 and first roller 650 can be prevented. In addition, the material clinging to the first roller 650 passes the first seal 610, contacts and adheres to the web W, and is conveyed downstream in the conveyance direction of the web W.

Note that if the first seal 610 is disposed to contact the outside surface F of the first roller 650 at an angle θ1 of 45 degrees (see FIG. 4B), the first seal 610 makes diagonal contact with the first roller 650, making accumulation of material in the area of contact between the first seal 610 and first roller 650 even more difficult.

A second roller 651 is disposed on the upstream side in the conveyance direction of the web W from the first roller 650. A second seal 620 is disposed to the second wall 600 b opposite the first wall 600 a of the first housing 600 to contact the second roller 651. The second seal 620 in the embodiment of the invention is disposed to the outside surface of the second wall 600 b. The second seal 620 and the second roller 651 contact each other.

As shown in FIG. 2B, the second roller 651 is disposed with its axis of rotation in the direction transverse to the conveyance direction of the web W (widthwise to the web W). The length of the second roller 651 is the same as the width of the frame 601 of the first housing 600 (the width of the web W).

The second roller 651 is connected to a drive device (not shown in the figure) such as a motor that drives the second roller 651. By driving the drive device, the second roller 651 can be turned on its axis of rotation (counterclockwise in FIG. 2B). The drive speed (circumferential speed) of the second roller 651 is set to the same speed as the conveyance speed (speed of travel) of the web W by the mesh belt 72. The second roller 651 is also disposed to contact the outside surface (accumulation surface) 72 a of the mesh belt 72.

Asperities Nf are also formed in the outside surface P of the second roller 651. The asperities Nf are formed in the area of the outside surface F of the second roller 651 that contacts the area where the web W is formed on the mesh belt 72. As shown in FIG. 3A, in this embodiment of the invention the asperities Nf are formed over the entire outside surface F of the second roller 651. The asperities Nf formed on the outside surface F of the second roller 651 are the same as the asperities Nf on the first roller 650, and further description thereof is omitted (see FIG. 3A and FIG. 3B). The configuration of the second seal 620 is also the same as the configuration of the first seal 610, and further description thereof is omitted. In addition, contact between the second seal 620 and second roller 651 is also the same as contact between the first seal 610 and first roller 650, and further description thereof is omitted (see FIG. 4A and FIG. 4B).

Operation in the area around the second roller is described next. When driving the sheet manufacturing apparatus 100, material including fiber from the opening in the drum 61 accumulates on the mesh belt 72. The accumulated material (web W) is conveyed by movement of the mesh belt 72. At this time, the second roller 651 also turns in contact with the mesh belt 72 by the movement of the mesh belt 72 (counterclockwise in FIG. 2A). At this time, remaining material of the web W that did not separate from the mesh belt 72, that is, material sticking to the surface of the mesh belt 72, may cling to the outside surface F of the second roller 651. In this event, the clinging material is held by the asperities Nf formed on the outside surface F of the second roller 651 and moves rotationally in conjunction with rotation of the second roller 651. In addition, in the area where the second seal 620 and the second roller 651 contact each other, the distal ends of the fibers H of the second seal 620 curve in the direction of rotation of the second roller 651 due to friction with the asperities Nf of the second roller 651 (the distal ends of the fibers H bend up in FIG. 2A). As a result, the material clinging to the second roller 651 is easily conveyed in the direction the distal ends of the fibers H of the second seal 620 bend. The material clinging to the second roller 651 is held by the asperities Nf, and passes through the area of contact between the second seal 620 and second roller 651 without being wiped off by the second seal 620. As a result, material clumping (agglomerating) near the area of contact between the first seal 610 and first roller 650 can be prevented. In addition, the material clinging to the second roller 651 passes the second seal 620, contacts and adheres to (or is pulled by) the mesh belt 72, and is conveyed downstream in the conveyance direction of the web W. The material conveyed downstream in the conveyance direction is, for example, suctioned by the suction mechanism (second air flow generator) 76.

Note that a side seal 690 that contacts the mesh belt 72 is disposed to the side walls 600 c other than the first wall 600 a and second wall 600 b of the first housing 600. The side seal 690 is also a pile seal, is configured like the pile seals described above, and further description thereof is omitted (see FIG. 2B).

The seal structure of the suction mechanism (second air flow generator) is described next. As shown in FIG. 2A, the sheet manufacturing apparatus 100 has a conveyor 700 including a mesh member (mesh belt 72) that conveys the web W, and a suction device (suction mechanism (second air flow generator) 76) that suctions the material including fiber onto the mesh belt 72. The suction mechanism 76 has a second housing 760 that defines the suction area. A third roller 652 that contacts the mesh belt 72 is disposed to a position opposite the first roller 650 with the mesh belt 72 therebetween. A third seal 630 disposed to the second housing 760 contacts the outside surface F of the third roller 652.

The third seal 630 is disposed to a side wall 760 a on one side of the second housing 760 (downstream in the conveyance direction of the web W), and contacts the outside surface F of the third roller 652. The side wall 760 a includes the outside surface, inside surface, and end (the surface facing the mesh belt 72) of the second housing 760. Note that the third seal 630 in this embodiment of the invention is disposed to the outside surface of the side wall 760 a.

The third roller 652 is disposed with its axis of rotation in the direction transverse to the conveyance direction of the web W (widthwise to the web W). The length of the third roller 652 is the same as the width of the first roller 650. The third roller 652 is a follower roller that rotates on its axis of rotation (clockwise in FIG. 2A) in conjunction with movement of the mesh belt 72.

The third roller 652 is disposed with its axis of rotation in a fixed position so that the third roller 652 contacts the inside surface 72 b of the mesh belt 72. As a result, even if a load is applied in the direction of gravity, the first roller 650 is supported by the third roller 652 through the web w and mesh belt 72. The position of the mesh belt 72 is also limited by the third roller 652. Therefore, the mesh belt 72 is supported with the accumulation surface of the mesh belt 72 held in a substantially horizontal position without sagging down by pressure from the first roller 650 or gravity.

Asperities Nf are formed on the outside surface F of the third roller 652. The asperities Nf formed on the outside surface F of the third roller 652 are the same as the asperities Nf on the first roller 650, and further description thereof is omitted (see FIG. 3A and FIG. 3B). The configuration of the third seal 630 is also the same as the configuration of the first seal 610, and further description thereof is omitted. In addition, contact between the third seal 630 and third roller 652 is also the same as contact between the first seal 610 and first roller 650, and further description thereof is omitted (see FIG. 4A and FIG. 4B). This configuration substantially seals the second housing 760 and improves the suction performance of the suction mechanism 76.

Operation in the area around the third roller is described next. FIG. 5B schematically illustrates operation in the area around the third roller. When driving the sheet manufacturing apparatus 100, material including fiber from the opening in the drum 61 accumulates on the mesh belt 72. The accumulated material (web W) is conveyed by movement of the mesh belt 72. At this time, the third roller 652 also turns in contact with the mesh belt 72 (clockwise in FIG. 2A and FIG. 5B). Material forming the web W may also stick to the outside surface F of the third roller 652 at this time. In this event, the clinging material is held by the asperities Nf formed on the outside surface F of the third roller 652 and moves rotationally in conjunction with rotation of the third roller 652. In addition, in the area where the third seal 630 and third roller 652 touch, the distal ends of the fibers H of the third seal 630 curve in the direction of rotation of the third roller 652 due to friction with the asperities Nf of the third roller 652 (the distal ends of the fibers H bend up in FIG. 5B). As a result, the material clinging to the third roller 652 is easily conveyed in the direction the distal ends of the fibers H of the third seal 630 bend. The material clinging to the third roller 652 is held by the asperities Nf, and passes through the area of contact between the third seal 630 and third roller 652 without being wiped off by the third seal 630. As a result, material clumping (agglomerating) near the area of contact between the third seal 630 and third roller 652 can be prevented. In addition, the material clinging to the third roller 652 passes the third seal 630, adheres to (or is pulled by) the mesh belt 72, and is conveyed in the direction of rotation of the mesh belt 72. The material sticking to the mesh belt 72 is suctioned by the suction mechanism 76.

A fourth roller 653 that contacts the mesh belt 72 is disposed to a position opposite the second roller 651 with the mesh belt 72 therebetween. A fourth seal 640 that contacts the outside surface F of the fourth roller 653 is disposed to the second housing 760.

The fourth seal 640 is disposed to a side wall 760 b opposite (on the upstream side in the conveyance direction of the web W) side wall 760 a of the second housing 760, and contacts the outside surface F of the fourth roller 653. The side wall 760 b includes the outside surface, inside surface, and end (the surface facing the mesh belt 72) of the second housing 760. Note that the fourth seal 640 in this embodiment of the invention is disposed to the outside surface of the side wall 760 b.

The fourth roller 653 is disposed with its axis of rotation in the direction transverse to the conveyance direction of the web N (widthwise to the web W). The length of the fourth roller 653 is the same as the width of the second roller 651. The fourth roller 653 is a follower roller that rotates on its axis of rotation (clockwise in FIG. 2A) in conjunction with movement of the mesh belt 72.

The fourth roller 653 is disposed with its axis of rotation in a fixed position so that the fourth roller 653 contacts the inside surface 72 b of the mesh belt 72. As a result, even if a load is applied in the direction of gravity, the second roller 651 is supported by the fourth roller 653 through the mesh belt 72. The position of the mesh belt 72 is also limited by the fourth roller 653. Therefore, the mesh belt 72 is supported with the accumulation surface of the mesh belt 72 held in a substantially horizontal position without sagging down due to pressure from the second roller 651 or gravity.

Asperities Nf are disposed to the outside surface F of the fourth roller 653. The asperities Nf formed on the outside surface F of the fourth roller 653 are the same as the asperities Nf on the first roller 650, and further description thereof is omitted (see FIG. 3A and FIG. 3B). The configuration of the fourth seal 640 is also the same as the configuration of the first seal 610, and further description thereof is omitted. In addition, contact between the fourth seal 640 and fourth roller 653 is also the same as contact between the first seal 610 and first roller 650, and further description thereof is omitted (see FIG. 4A and FIG. 4B). This configuration substantially seals the second housing 760 and improves the suction performance of the suction mechanism 76.

Operation in the area around the fourth roller is described next. When driving the sheet manufacturing apparatus 100, material including fiber from the opening in the drum 61 accumulates on the mesh belt 72. The accumulated material (web W) is conveyed by movement of the mesh belt 72. At this time, the fourth roller 653 also turns in contact with the mesh belt 72 (clockwise in FIG. 2A). Material forming the web W may also stick to the outside surface F of the fourth roller 653 at this time. In this event, the clinging material is held by the asperities Nf formed on the outside surface F of the fourth roller 653 and moves rotationally in conjunction with rotation of the fourth roller 653. In addition, in the area where the fourth seal 640 and fourth roller 653 touch, the distal ends of the fibers H of the fourth seal 640 curve in the direction of rotation of the fourth roller 653 due to friction with the asperities Nf of the fourth roller 653 (the distal ends of the fibers H bend up in FIG. 2B). As a result, the material clinging to the fourth roller 653 is easily conveyed in the direction the distal ends of the fibers H of the fourth seal 640 bend. The material clinging to the fourth roller 653 is held by the asperities Nf, and passes through the area of contact between the fourth seal 640 and fourth roller 653 without being wiped off by the fourth seal 640. As a result, material clumping (agglomerating) near the area of contact between the fourth seal 640 and fourth roller 653 can be prevented. In addition, the material clinging to the fourth roller 653 passes the fourth seal 640, adheres to (or is pulled by) the mesh belt 72, and is conveyed in the direction of rotation of the mesh belt 72. The material sticking to the mesh belt 72 is suctioned by the suction mechanism 76.

Effects of this embodiment are described below.

Asperities Nf creating a surface roughness greater than or equal to 30 μm and less than or equal to 500 μm are disposed to the outside surface F of the first roller 650. A first seal 610 is disposed touching the outside surface F. As a result, material clinging to the outside surface F of the first roller 650 passes the first seal 610 and is conveyed forward without being removed by the first seal 610. Therefore, clumps of material forming in the area where the first seal 610 and first roller 650 are in contact with each other, and near the border to this contact area, is suppressed, and sheets of consistent quality can be produced. Note that the same effect is achieved at the second roller 651 and second seal 620.

In addition, formation of clumps of material is also suppressed by the third and fourth roller 652, 653 and the third and fourth seal 630, 640 in the same way as by the first and second roller 650, 651 and the first and second seal 610, 620. As a result, damage to the mesh belt 72, and increasing the drive load, can be suppressed. Yet further, the frequency of maintenance of the sheet manufacturing apparatus 100 (such as the air-laying device 60, second web forming device 70, and conveyor 700) can be reduced.

Embodiment 2

A sheet manufacturing apparatus according to a second embodiment of the invention is described next. Note that the basic configuration of the sheet manufacturing apparatus according to this embodiment is the same as the configuration of the first embodiment, and a configuration that differs, that is, the configuration of the first roller, is described below. FIG. 6A is an external view illustrating the configuration of the first roller according to this embodiment, and FIG. 6B is a partial section view illustrating the configuration of the first roller. In addition, FIG. 6C is an external view illustrating the configuration of another first roller according to this embodiment.

The first roller 650 a contacts the web W conveyed by the conveyor 700, and as shown in FIG. 6A and FIG. 6B, has a channel T with a depth greater than or equal to 30 μm and less than or equal to 500 μm formed in the direction transverse to the direction of rotation of the first roller 650 a formed in the outside surface F of the first roller 650 a. Note that the channel T is one form of asperities. The depth d of the channel T is specified as described above for the same reason as the asperities Nf in the first roller 650, and achieves the same conveyance of material clinging to the outside surface F of the first roller 650 a, sealing properties, and sheet uniformity.

The channel T is formed in the direction crosswise to the direction of rotation of the first roller 650 a. More specifically, the angle θ2 of the channel T to the direction of rotation of the first roller 650 a is desirably an angle other than 0° (360°) or 180°. The angle θ2 of the channel T is therefore at least 0.1°, for example. In addition, the angle θ2 of the channel T may be 90° (perpendicular to the direction of rotation of the first roller 650 a).

The configuration of the channel T may like a single start screw configured with a single channel T formed in a continuous spiral (a single start screw thread), or a like a multi-start screw configured with a plurality of channels T formed in a spiral (such as channels in a double start screw thread). As shown in FIG. 6B, the shape of the channel T is formed so that the width W1 of the root of the channel T in section view, and the width W2 of the outside surface F (crest of the channel T) of the first roller 650 a, are substantially equal dimensions. The thread angle θ3 is greater than or equal to 60° and less than or equal to 120°.

The configuration of the channel T is not limited to the configuration described above. As shown in FIG. 6C, for example, the channel T of the first roller 650 a′ may be formed so that channels T intersect in a knurled pattern (diamond or cross-hatch).

The outside surface F of the first roller 650 a and the fibers H of the first seal 610 are also configured to contact. Note that the configuration of the first seal 610 is the same as in the configuration of the first embodiment, and further description thereof is omitted. In addition, contact between the first seal 610 and the first roller 650 a is the same as in the first embodiment of the invention, and further description thereof is omitted (see FIG. 4A and FIG. 4B).

When driving the sheet manufacturing apparatus 100, and material forming the web W sticks to the outside surface F of the first roller 650 a, the clinging material is held by the channel T formed in the outside surface F of the first roller 650 a, and rotates in conjunction with rotation of the first roller 650 a. In addition, in the area where the first seal 610 and first roller 650 a touch, the distal ends of the fibers H of the first seal 610 curve in the direction of rotation of the first roller 650 a due to friction with the channel T of the first roller 650 a (see FIG. 5A). As a result, the material clinging to the first roller 650 a is easily conveyed in the direction the distal ends of the fibers H of the first seal 610 bend. The material clinging to the first roller 650 a is held by the channel T, and passes through the area of contact between the first seal 610 and first roller 650 a without being wiped off by the first seal 610. As a result, material clumping (agglomerating) near the area of contact between the first seal 610 and first roller 650 a can be prevented. In addition, the material clinging to the first roller 650 a passes the first seal 610, contacts and adheres to the web w, and is conveyed downstream in the conveyance direction of the web W. The same effect is achieved when using first roller 650 a′.

Effects of this embodiment are described below.

A channel T with a depth d greater than or equal to 30 μm and less than or equal to 500 μm is formed as ridges and valleys on the outside surface F of the first roller 650 a, 650 a′. A first seal 610 is disposed touching the outside surface F. As a result, material clinging to the outside surface F of the first roller 650 a passes the first seal 610 and is conveyed forward without being removed by the first seal 610. Therefore, clumps of material forming in the area where the first seal 610 and first roller 650 a are in contact with each other, and near the border to this contact area, is suppressed, and sheets of consistent quality can be produced.

Note that the configuration of the first roller 650 a, 650 a′ according to this embodiment can also be applied to the second, third, and fourth roller 651, 652, 653 in the first embodiment described above (as second roller 651 a, 651 a′, third roller 652 a, 652 a′, and fourth roller 653 a, 653 a′). As a result, the same effect can be achieved with the second roller 651 a (651 a′) and second seal 620. Formation of material clumps at the third and fourth roller 652 a, 653 a (652 a, 653 a′) and the third and fourth seal 630, 640 can also be achieved as described above, and as a result damage to the mesh belt 72, and increasing the drive load, can be suppressed. Yet further, the frequency of maintenance of the sheet manufacturing apparatus 100 can be reduced.

Embodiment 3

A sheet manufacturing apparatus according to a third embodiment of the invention is described next. Note that the basic configuration of the sheet manufacturing apparatus according to this embodiment is the same as the configuration of the first embodiment, and a configuration that differs, that is, the configuration of the first roller, is described below. FIG. 7A is an external view illustrating the configuration of the first roller according to this embodiment, and FIG. 7B is a partial section view of the configuration of the first roller.

The first roller 650 b contacts the web W conveyed by the conveyor 700, and as shown in FIG. 7A and FIG. 7B, has asperities Nf in the shape of a screen formed the outside surface F of the first roller 650 b. More specifically, the first roller 650 b has a cylindrical base B, and mesh M covering the surface of the base B. The base B is made of aluminum alloy or stainless steel, for example, and the mesh M is made from stainless steel, polyester, polyethylene, nylon, or other metal material or plastic material.

The mesh M is, for example, preferably from 10 mesh 0.5 mm wire (10 openings per inch) to 500 mesh 0.02 mm wire (500 openings per inch). This achieves good conveyance of material clinging to the outside surface F of the first roller 650 b, sealing properties, and sheet uniformity.

The outside surface F of the first roller 650 b and the fibers H of the first seal 610 are also configured to contact. Note that the configuration of the first seal 610 is the same as in the configuration of the first embodiment, and further description thereof is omitted. In addition, contact between the first seal 610 and the first roller 650 b is the same as in the first embodiment of the invention, and further description thereof is omitted (see FIG. 4A and FIG. 4B).

When driving the sheet manufacturing apparatus 100, and material forming the web W sticks to the outside surface F of the first roller 650 a, the clinging material is held by the asperities Nf (openings in the mesh M) formed in the outside surface F of the first roller 650 b, and rotates in conjunction with rotation of the first roller 650 b. In addition, in the area where the first seal 610 and first roller 650 b touch, the distal ends of the fibers H of the first seal 610 curve in the direction of rotation of the first roller 650 b due to friction with the asperities Nf (mesh M) of the first roller 650 b (see FIG. 5A). As a result, the material clinging to the first roller 650 b is easily conveyed in the direction the distal ends of the fibers H of the first seal 610 bend. The material clinging to the first roller 650 b is held by the asperities Nf, and passes through the area of contact between the first seal 610 and first roller 650 b without being removed by the first seal 610. As a result, material clumping (agglomerating) can be prevented. In addition, the material clinging to the first roller 650 b passes the first seal 610, contacts and adheres to the web W, and is conveyed downstream in the conveyance direction of the web W.

Effects of this embodiment are described below.

Asperities Nf are formed in a screen pattern by mesh M on the outside surface F of the first roller 650 b. A first seal 610 is disposed touching the outside surface F. As a result, material clinging to the outside surface F of the first roller 650 b passes the first seal 610 and is conveyed forward without being removed by the first seal 610. Therefore, clumps of material forming in the area where the first seal 610 and first roller 650 b are in contact with each other, and near the border to this contact area, is suppressed, and sheets of consistent quality can be produced.

Note that the configuration of the first roller 650 b according to this embodiment can also be applied to the second, third, and fourth roller 651, 652, 653 (as second, third, and fourth roller 651 b, 652 b, 653 b). As a result, the same effect can be achieved with the second roller 651 b and second seal 620. Formation of material clumps at the third and fourth roller 652 b, 653 b and the third and fourth seal 630, 640 can also be achieved as described above, and as a result damage to the mesh belt 72, and increasing the drive load, can be suppressed. Yet further, the frequency of maintenance of the sheet manufacturing apparatus 100 can be reduced.

Embodiment 4

A sheet manufacturing apparatus according to a fourth embodiment of the invention is described next. In a sheet manufacturing apparatus according to the first embodiment to third embodiment of the invention, configurations applying the first roller, for example, to the air-laying device are described, but this embodiment of the invention applies the first roller, for example, to the wetting device. FIG. 8 schematically illustrates the configuration of the wetting device. Note that FIG. 8 illustrates the configuration without showing the air-laying device.

The wetting device 78 wets the web W deposited by the air-laying device 60. The wetting device 78 includes a generator 170, a third housing 172, and a first air flow generator 176.

The generator 170 is disposed on the outside surface 72 a side of the mesh belt 72. In FIG. 8, the generator 170 is disposed outside the area enclosed by the mesh belt 72. The generator 170 generates fluid droplets or a high humidity gas. The generator 170 may generate fluid droplets by ultrasonic waves. The generator 170 may, for example, apply ultrasonic waves at a frequency of 20 kHz to several MHz to fluid (water) to generate minute fluid droplets ranging from several nanometers to several microns. The generator 170 may also produce steam to generate a high humidity gas. High humidity gas as used here means a gas at greater than or equal to 70% and less than or equal to 100% relative humidity.

The third housing 172 is connected to the generator 170 through a conduit 171. The third housing 172 is disposed on the outside surface 72 a side. The third housing 172 is shaped like a box, for example, and has an opening facing the outside surface 72 a of the mesh belt 72. The third housing 172 defines the wetting area for wetting the web w. The wetting device 78 can wet the web W deposited on the outside surface 72 a in the wetting area.

The first roller 650 that contacts the web W conveyed by the mesh belt 72 is disposed on the downstream side of the third housing 172 in the conveyance direction of the web W. A first seal 610 that contacts the outside surface of the first roller 650 is disposed to the first wall 172 a of the third housing 172. The first seal 610 contacts the first roller 650. Asperities Nf are formed by processing the outside surface F of the first roller 650 to a surface roughness of greater than or equal to 30 μm and less than or equal to 500 μm. The detailed configuration of the first seal 610 and first roller 650 is the same as in the first embodiment, and further description thereof is omitted.

A second roller 651 is disposed on the upstream side of the first roller 650 in the conveyance direction of the web W. A second seal 620 that contacts the second roller 651 is disposed to the second wall 172 b opposite the first wall 172 a of the third housing 172. The second seal 620 contacts the second roller 651. Asperities Nf are formed by processing the outside surface F of the second roller 651 to a surface roughness of greater than or equal to 30 μm and less than or equal to 500 μm. The asperities Nf are disposed in the area of the outside surface F of the second roller 651 that contacts the web W. The detailed configuration of the second seal 620 and second roller 651 is the same as in the first embodiment, and further description thereof is omitted.

The first air flow generator 176 is disposed on the inside surface 72 b side of the mesh belt 72. In FIG. 8, the first air flow generator 176 is disposed inside the area surrounded by the mesh belt 72. The first air flow generator 176 is disposed opposite the third housing 172 with the mesh belt 72 therebetween. The first air flow generator 176 produces an air flow through the web W in the thickness direction. This air flow is a current intersecting the outside surface 72 a, and in this example is a current in the direction perpendicular to the outside surface 72 a. The wetting device 78 can supply fluid droplets or high humidity gas to the web W by the air flow generated by the first air flow generator 176. The fluid droplets or high humidity gas is carried through the thickness of the web W by the air flow. The mass of the fluid droplets supplied by the wetting device 78 to the web W is, in this example, greater than or equal to 0.1% and less than or equal to 3% of the mass of the web W per unit volume of the web W. In the example in the figure, the first air flow generator 176 is a suction device (first suction device) that suctions fluid droplets or high humidity gas generated by the generator 170 from the inside surface 72 b side. The first air flow generator 176 has a fourth housing 177 disposed below the mesh belt 72 with an opening facing the inside surface 72 b. A vacuum blower that suctions air inside the fourth housing 177 is connected.

A third roller 652 that contacts the mesh belt 72 is disposed to a position opposite the first roller 650 with the mesh belt 72 therebetween. A third seal 630 disposed to the fourth housing 177 contacts the outside surface F of the third roller 652.

The third seal 630 is disposed to the side wall 177 a on the downstream side of the fourth housing 177 in the conveyance direction of the web W, and contacts the outside surface F of the third roller 652. Asperities Nf producing a surface roughness of greater than or equal to 30 μm and less than or equal to 500 μm are formed on the outside surface F of the third roller 652. Note that the detailed configuration of the third seal 630 and third roller 652 is the same as described in the first embodiment of the invention, and further description thereof is omitted.

A fourth roller 653 that contacts the mesh belt 72 is disposed to a position opposite the second roller 651 with the mesh belt 72 therebetween. A fourth seal 640 disposed to the side wall 177 b opposite the side wall 177 a of the fourth housing 177 (on the upstream side in the conveyance direction of the web W) contacts the outside surface F of the fourth roller 653. Asperities Nf producing a surface roughness of greater than or equal to 30 μm and less than or equal to 500 μm are formed on the outside surface F of the fourth roller 653. Note that the detailed configuration of the fourth seal 640 and the fourth roller 653 is the same as described in the first embodiment of the invention, and further description thereof is omitted.

Note that by using a first and second roller 650, 651 and a first and second seal 610, 620 in the wetting device 78 and not only in the air-laying device 60, the occurrence of material clumps is suppressed, and sheets of consistent quality can be produced. The occurrence of material clumps can also be suppressed at the third and fourth roller 652, 653 and the third and fourth seal 630, 640, and as a result damage to the mesh belt 72, and increasing the drive load, can be suppressed. Yet further, the frequency of maintenance of the sheet manufacturing apparatus 100 (such as the wetting device 78 and mesh belt 72) can be reduced.

Note also that first to fourth rollers 650 a, 650 a′, 651 a, 651 a′, 652 a, 652 a′, 653 a, 653 a′ (see the second embodiment of the invention), or first to fourth rollers 650 b, 651 b, 652 b, 653 b (see the third embodiment of the invention) may be used in the wetting device 78 instead of first to fourth rollers 650, 651, 652, 653.

Embodiment 5

A sheet manufacturing apparatus according to a fifth embodiment of the invention is described next. In a sheet manufacturing apparatus according to the first embodiment to fourth embodiment of the invention, configurations applying the first roller, for example, to the air-laying device or wetting device are described, but this embodiment of the invention describes a configuration applying the first roller, for example, to the classifier. FIG. 9 schematically illustrates the configuration of the classifier.

As shown in FIG. 9, the classifier 40 includes a foraminous drum 41; a fifth housing 400 covering the drum 41; a conveyor 460 on which material including fiber (first classified material) that has passed through the holes in the drum 41 accumulates as a web V, and which conveys the accumulated web V; a first roller 650 that contacts the web V conveyed by the conveyor 460, and has asperities Nf formed on the outside surface thereof; and a first seal 610 disposed to a first wall 400 a of the fifth housing 400 and touching the outside surface of the first roller 650.

The drum 41 includes a rotatable cylinder, and numerous holes through which at least material including fiber carried by air passes are formed in the cylinder. The fifth housing 400 has a frame 401, and is hollow inside. The drum 41 is placed inside the frame 401, and is thereby covered (surrounded) by the fifth housing 400. The fifth housing 400 does not have a floor panel, and is open.

The conveyor 460 accumulates material including fiber that has passed through the holes in the drum 41 as a web V, and conveys the accumulated web V. The conveyor 460 in this embodiment of the invention includes a mesh belt 46 and tension rollers 47.

On the downstream side of the fifth housing 400 in the conveyance direction of the web V is disposed a first roller 650 that contacts the web V conveyed by the mesh belt 46. Disposed to the first wall 400 a of the fifth housing 400 is a first seal 610, which contacts the outside surface of the first roller 650. The first seal 610 and first roller 650 contact each other. Asperities Nf producing a surface roughness of greater than or equal to 30 μm and less than or equal to 500 μm are formed on the outside surface F of the first roller 650. Note that the detailed configuration of the first seal 610 and the first roller 650 is the same as described in the first embodiment of the invention, and further description thereof is omitted.

The second roller 651 is disposed upstream from the first roller 650 in the conveyance direction of the web W. A second seal 620 is disposed to the second wall 400 b opposite the first wall 400 a of the fifth housing 400 and contacts the second roller 651. The second seal 620 contacts the second roller 651. Asperities Nf producing a surface roughness of greater than or equal to 30 μm and less than or equal to 500 μm are formed on the outside surface F of the second roller 651. The asperities Nf are formed in the area of the outside surface F of the second roller 651 that contacts the area where the web V is formed on the mesh belt 46. Note that the detailed configuration of the second seal 620 and the second roller 651 is the same as described in the first embodiment of the invention, and further description thereof is omitted.

In addition, as shown in FIG. 9, a suction device (suction mechanism) 48 is disposed on the inside surface 46 b side of the mesh belt 46. The suction device 48 is disposed opposite the fifth housing 400 with the mesh belt 46 therebetween. The suction device 48 is located below the mesh belt 46, and has a sixth housing 480 with an opening facing the inside surface 46 b. A third roller 652 that contacts the mesh belt 46 is disposed to a position opposite the first roller 650 with the mesh belt 46 therebetween. A third seal 630 that contacts the outside surface F of the third roller 652 is also disposed to the sixth housing 480.

The third seal 630 is disposed to a side wall 480 a of the sixth housing 480 on the downstream side in the conveyance direction of the web V, and contacts the outside surface F of the third roller 652. Asperities Nf producing a surface roughness of greater than or equal to 30 μm and less than or equal to 500 μm are formed on the outside surface F of the third roller 652. Note that the detailed configuration of the third seal 630 and the third roller 652 is the same as described in the first embodiment of the invention, and further description thereof is omitted.

Also in this embodiment of the invention, a fourth roller 653 that contacts the mesh belt 46 is disposed to a position opposite the second roller 651 with the mesh belt 46 therebetween. A fourth seal 640 that contacts the outside surface F of the fourth roller 653 is disposed to a side wall 480 b opposite (on the upstream side in the conveyance direction of the web V) side wall 480 a of the sixth housing 480, and contacts the outside surface F of the fourth roller 653. Asperities Nf producing a surface roughness of greater than or equal to 30 μm and less than or equal to 500 μm are formed on the outside surface F of the fourth roller 653. Note that the detailed configuration of the fourth seal 640 and the fourth roller 653 is the same as described in the first embodiment of the invention, and further description thereof is omitted.

By using a first and second roller 650, 651 and a first and second seal 610, 620 in the classifier 40 and not only in the air-laying device 60 and the wetting device 78 in this embodiment of the invention, the occurrence of material clumps is suppressed, and sheets of consistent quality can be produced. The occurrence of material clumps can also be suppressed at the third and fourth roller 652, 653 and the third and fourth seal 630, 640, and as a result damage to the mesh belt 46, and increasing the drive load, can be suppressed. Yet further, the frequency of maintenance of the sheet manufacturing apparatus 100 (such as the first web forming device 45 and conveyor 460) can be reduced.

Note also that first roller 650 a, 650 a′, second roller 651 a, 651 a′, third roller 652 a, 652 a′, and fourth roller 653 a, 653 a′(see the second embodiment of the invention), or first, second, third, and fourth roller 650 b, 651 b, 652 b, 653 b (see the third embodiment of the invention) may be applied to the classifier 40 instead of first, second, third, and fourth roller 650, 651, 652, 653.

Embodiment 6

A sheet manufacturing apparatus according to a sixth embodiment of the invention is described next. The sheet manufacturing apparatus according to the first embodiment to fifth embodiment of the invention describe configurations having a first roller with a textured surface (asperities) on the outside, but the invention is not so limited and may be configured with a first roller that does not have a textured outside surface.

A sheet manufacturing apparatus according to this embodiment of the invention has a foraminous drum; a housing covering the drum; a conveyor on which material including fiber that has passed through the holes in the drum accumulates as a web, and which conveys the deposited web; a first roller that contacts the web conveyed by the conveyor; and a first seal, which is a first seal disposed to a first wall of the housing and contacts the outside surface of the first roller, is disposed to contact the outside surface F of the first roller at an angle greater than or equal to 45 degrees and less than or equal to 90 degrees to a virtual vertical plane tangent to the outside surface of the first roller.

Note that the configuration of the drum and conveyor, for example, in this embodiment are the same as described in the first embodiment of the invention, and further description thereof is omitted.

FIG. 10A and FIG. 10B schematically illustrate contact between a first seal and first roller. The first roller 650 c is disposed with its axis of rotation in the direction transverse to the conveyance direction of the web W (widthwise to the web W), and is configured to turn as driven by a motor or other drive device. Note that asperities (Nf, T) as described in the foregoing embodiments are not disposed to the outside surface F of the first roller 650 c in this embodiment. The configuration of the first roller 650 c is otherwise the same as described in the above embodiments.

The first seal 610 in this example is a pile seal comprising a base FL and numerous fibers H planted densely on the one side of the base FL, and is configured as in the first embodiment.

As shown in FIG. 10A, the distal ends of the fibers H of the first seal 610 are configured to touch the outside surface F of the first roller 650 c. More specifically, as shown in FIG. 10A, the first seal 610 is disposed so that the angle θ1 of the first seal 610 to a virtual vertical plane 8P tangent to the outside surface F of the first roller 650 c is 90 degrees. Note that the distal ends of the fibers H in the first seal 610 are pushed against the outside surface F of the first roller 650.

Note that in FIG. 10A the angle θ1 of the first seal 610 to the virtual vertical plane SP to the outside surface F of the first roller 650 c is set to 90 degrees, but the invention is not limited to this configuration. The first seal 610 may be set to contact the outside surface F of the first roller 650 at any angle greater than or equal to 45 degrees and less than or equal to 90 degrees to the virtual vertical plane SP tangent to the outside surface F of the first roller 650.

As shown in FIG. 10B, for example, the first seal 610 may be disposed to contact the outside surface F of the first roller 650 c at an angle θ1 of 45 degrees to the virtual vertical plane SP tangent to the outside surface F of the first roller 650 c. If the angle θ1 is within the foregoing range, a good seal can be assured between the first seal 610 and first roller 650 c.

By setting the first seal 610 to contact the first roller 650 c from a diagonal direction, this embodiment of the invention makes material sticking to the first seal 610 more difficult.

Note that the configuration described above may also be applied to other configurations. In this case, the same effect can be achieved at the second roller 651 and the second seal 620. In addition, formation of clumps of material is also suppressed by the third and fourth roller 652, 653 and the third and fourth seal 630, 640 in the same way, and as a result damage to the mesh belt, and increasing the drive load, can be suppressed. Yet further, the frequency of maintenance of the sheet manufacturing apparatus 100 can be reduced.

Embodiment 7

A sheet manufacturing apparatus according to a seventh embodiment of the invention is described next. Note that the basic configuration of a sheet manufacturing apparatus according to this embodiment is the same as the configuration of the first embodiment, and further description thereof is omitted. FIG. 11A schematically illustrates the configuration of an air-laying device, and FIG. 11B is an oblique view of part of the air-laying device. FIG. 12A is an external view illustrating the configuration of a first roller, and FIG. 12B is a partial section view illustrating the configuration of the first roller. FIG. 13A and FIG. 13B schematically illustrate contact between the first seal and the first roller. Note that the configuration of the wetting device is omitted in FIG. 11A.

This embodiment of the invention has round recesses Cf disposed to the surface (outside surface F) of the first roller 650 d. The recesses Cf are disposed in the area of the outside surface F of the first roller 650 d that contacts the web W. As shown in FIG. 12A, in this embodiment of the invention the recesses Cf are formed over the entire outside surface F of the first roller 650 d.

As shown in FIG. 12B, the recesses Cf in this embodiment are numerous small recesses (dimples, or spherical recesses, or crater-shaped recesses) formed in the outside surface of the first roller 650 d. The depth H of the recesses Cf (the distance from the root to the crest of the recesses Cf) is greater than or equal to 30 μm and less than or equal to 500 μm. The width of the recesses Cf (the distance from one recess Cf crest to the adjacent crest, the diameter of round recesses Cf) is greater than or equal to 0.1 mm and less than or equal to 2 ms. The first roller 650 d is a metal roller made of aluminum or stainless steel, for example, and round recesses Cf are formed in the surface of the first roller 650 d by, for example, blasting the surface with spherical grit (such as glass beads with an average particle diameter of 1.2 mm). Compared with blasting the surface with multifaceted alumina having an average particle diameter of 0.3 ms, this reduces formation of sharp edges (small protrusions with a sharp needle-like tips, such as burrs) on the roller surface. In addition, because the width D of the recesses Cf can be increased, resin or other particles entering (becoming stuck) in the recesses Cf, or resin in the recesses Cf sticking to the material, can be prevented.

Note that round recesses Cf can be formed by methods other than blasting with spherical grit, including, for example, formation by roll forming or chemical processing.

Forming the recesses Cf disposed in the outside surface F of the first roller 650 c with a depth H greater than or equal to 30 μm and less than or equal to 500 μm makes it difficult for material including fiber adhering to the outside surface F of the first roller 650 d to be left (accumulate) on the first seal 610 when conveyed in the direction of rotation of the first roller 650 d. In addition, because the width D of the recesses Cf is greater than or equal to 0.1 mm and less than or equal to 2 m, sticking of material, for example, to the outside surface F of the first roller 650 d can be suppressed.

Note that if the depth H of the recesses Cf is less than 30 μm, the effect of inhibiting material remaining (accumulating) on the first seal 610 is reduced. If the depth H of the recesses Cf exceeds 500 μm, the gap between the recesses Cf and the first seal 610 increases, and the seal effect may drop. In addition, the pattern of the recesses Cf may be transferred to the web W of the depth H of the recesses Cf is great, and the quality of the sheet may drop.

Furthermore, if the width D of the recesses Cf is less than 0.1 mm, sharp protrusions may be formed on the outside surface F, and material (including fiber and resin) may be caught and stick to the protrusions. Furthermore, if the width D of the recesses Cf is greater than 2.0 mm, a poor seal may result and pressure on the web w may drop.

Note that the depth H and width D of the recesses Cf can be measured using various measuring instruments, including a surface roughness tester or laser scanning microscope.

Surface processing to improve wear resistance is also applied to the outside surface F of the first roller 650 d. For example, anodizing or plating may be applied. Such surface processes are thin film processes forming a coating several microns thick. As a result, the shape of the recesses Cf can be retained while wear resistance can also be improved.

Surface processing to lower the surface free energy may also be applied to the outside surface F of the first roller 650 d. For example, fluorination (such as electroless Ni-P-PTEE composite plating) may be applied. Such surface processes are thin film processes forming a coating several microns thick. As a result, the shape of the recesses Cf can be retained while sticking of material (including fiber and resin) can be reduced.

The first seal 610 in this example is a pile seal comprising a base FL and numerous fibers H planted densely on the one side of the base FL (see FIG. 13A). The other side of the base FL of the first seal 610 is attached to the outside surface of the first wall 600 a of the first housing 600, and the distal ends of the fibers H of the first seal 610 are configured to touch the outside surface F of the first roller 650 d. More specifically, as shown in FIG. 13A, the first seal 610 is disposed so that the angle θ1 of the first seal 610 to a virtual vertical plane SP tangent to the outside surface F of the first roller 650 d is 90 degrees. More specifically, the first seal 610 and first roller 650 d are disposed so that the distal ends of the fibers H of the first seal 610 are substantially perpendicular to the virtual vertical plane SP. Note that the distal ends of the fibers H in the first seal 610 are pushed against the outside surface F of the first roller 650 d. As a result, the gap between the outside surface of the first wall 600 a of the first housing 600 and the first roller 650 d is substantially closed by the first seal 610. In addition, when the first roller 650 d and the first seal 610 slide against each other as the first roller 650 d turns, wear and friction are suppressed compared with when a foam sponge is used as the first seal 610, and the drive load on the first roller 650 d can be reduced. The length of the fibers H of the first seal 610 is set so that the first seal 610 reliably contacts the first roller 650 d. For example, the length is set longer than the width of the gap between the first wall 600 a of the first housing 600 and the first roller 650 d.

Note that in FIG. 13A the angle θ1 of the first seal 610 is set to 90 degrees, but the invention is not limited to this configuration. The first seal 610 may be set to contact the outside surface F of the first roller 650 d at an angle greater than or equal to 45 degrees and less than or equal to 90 degrees to the virtual vertical plane SP tangent to the outside surface F of the first roller 650 d. As shown in FIG. 13B, for example, the first seal 610 may be disposed to contact the outside surface F of the first roller 650 at an angle θ1 of 45 degrees to the virtual vertical plane SP tangent to the outside surface F of the first roller 650 d. If the angle θ1 is within the foregoing range, a good seal can be assured between the first seal 610 and first roller 650 d.

Operation in the area around the first roller is described next. FIG. 14A schematically illustrates operation in the area around the first roller. When driving the sheet manufacturing apparatus 100, material including fiber from the opening in the drum 61 accumulates on the mesh belt 72. The accumulated material (web W) is conveyed by movement of the mesh belt 72. At this time, the first roller 650 d also turns in contact with the web W (counterclockwise in FIG. 11A and FIG. 14A). Material forming the web W may also stick to the outside surface F of the first roller 650 d at this time.

Note that because round recesses Cf are formed on the outside surface F of the first roller 650 d in this embodiment of the invention and there are no burrs or sharp parts, there is substantially no catching and sticking of material on the outside surface F of the first roller 650 d.

Sticking material is held by the recesses Cf formed on the outside surface F of the first roller 650 d and moves rotationally in conjunction with rotation of the first roller 650 d. In addition, in the area where the first seal 610 and first roller 650 d touch, the distal ends of the fibers H of the first seal 610 curve in the direction of rotation of the first roller 650 d due to friction with the recesses Cf of the first roller 650 d (the distal ends of the fibers H bend down in FIG. 14A). As a result, the material clinging to the first roller 650 d is easily conveyed in the direction the distal ends of the fibers H of the first seal 610 bend. The material clinging to the first roller 650 d is held by the recesses Cf, and passes through the area of contact between the first seal 610 and first roller 650 d without being wiped off by the first seal 610. As a result, material clumping (agglomerating) near the area of contact between the first seal 610 and first roller 650 d can be prevented. In addition, the material clinging to the first roller 650 d passes the first seal 610, contacts and adheres to the web W, and is conveyed downstream in the conveyance direction of the web W.

It is also difficult for material to enter (become stuck in) the recesses Cf of the first roller 650 d, and the first roller 650 d is therefore driven without material (fiber or resin) sticking to its surface.

Note that if the first seal 610 is disposed to contact the outside surface F of the first roller 650 d at an angle θ1 of 45 degrees (see FIG. 13B), the first seal 610 makes diagonal contact with the first roller 650 d, making accumulation of material in the area of contact between the first seal 610 and first roller 650 d even more difficult.

A second roller 651 is disposed on the upstream side in the conveyance direction of the web W from the first roller 650 d. A second seal 620 is disposed to the second wall 600 b opposite the first wall 600 a of the first housing 600 to contact the second roller 651 d. The second seal 620 in this embodiment of the invention is disposed to the outside surface of the second wall 600 b. The second seal 620 and the second roller 651 d contact each other.

As shown in FIG. 11B, the second roller 651 is disposed with its axis of rotation in the direction transverse to the conveyance direction of the web W (widthwise to the web W). The length of the second roller 651 d is the same as the width of the frame 601 of the first housing 600 (the width of the web W).

The second roller 651 d is connected to a drive device (not shown in the figure) such as a motor that drives the second roller 651 d. By driving the drive device, the second roller 651 d can be turned on its axis of rotation (counterclockwise in FIG. 11B). The drive speed (circumferential speed) of the second roller 651 d is set to the same speed as the conveyance speed (speed of travel) of the web W by the mesh belt 72. The second roller 651 d is also disposed to contact the outside surface (accumulation surface) 72 a of the mesh belt 72.

Round recesses Cf are also formed in the outside surface F of the second roller 651 d. The recesses Cf are formed in the area of the outside surface F of the second roller 651 d that contacts the area where the web W is formed on the mesh belt 72. As shown in FIG. 12A, in this embodiment of the invention the recesses Cf are formed over the entire outside surface F of the second roller 651 d. The recesses Cf formed on the outside surface F of the second roller 651 d are the same as the recesses Cf formed on the first roller 650 d, and further description thereof is omitted (see FIG. 12A and FIG. 12B). The configuration of the second seal 620 is also the same as the configuration of the first seal 610, and further description thereof is omitted.

In addition, contact between the second seal 620 and second roller 651 d is also the same as described above, and further description thereof is omitted (see FIG. 13A and FIG. 13B).

Operation in the area around the second roller is described next. When driving the sheet manufacturing apparatus 100, material including fiber from the opening in the drum 61 accumulates on the mesh belt 72. The accumulated material (web W) is conveyed by movement of the mesh belt 72. At this time, the second roller 651 d also turns in contact with the mesh belt 72 by the movement of the mesh belt 72 (counterclockwise in FIG. 11A). At this time, remaining material of the web W that did not separate from the mesh belt 72, that is, material sticking to the surface of the mesh belt 72, may cling to the outside surface F of the second roller 651 d.

Note that because round recesses Cf are formed on the outside surface F of the second roller 651 d in this embodiment of the invention and there are no burrs or sharp parts, there is substantially no catching and sticking of material on the outside surface F of the second roller 651 d.

Sticking material is held by the recesses Cf formed on the outside surface F of the second roller 651 d and moves rotationally in conjunction with rotation of the second roller 651 d. In addition, in the area where the second seal 620 and second roller 651 d touch, the distal ends of the fibers H of the second seal 620 curve in the direction of rotation of the second roller 651 d due to friction with the recesses Cf of the second roller 651 d (the distal ends of the fibers H bend up in FIG. 11A). As a result, the material clinging to the second roller 651 d is easily conveyed in the direction the distal ends of the fibers H of the second seal 620 bend. The material clinging to the second roller 651 d is held by the recesses Cf, and passes through the area of contact between the second seal 620 and second roller 651 d without being wiped off by the second seal 620. As a result, material clumping (agglomerating) near the area of contact between the second seal 620 and second roller 651 d can be prevented. In addition, the material clinging to the second roller 651 d passes the second seal 620, contacts and adheres to (or is caught by) the mesh belt 72, and is conveyed downstream in the conveyance direction of the web W. The material conveyed downstream in the conveyance direction is, for example, suctioned by the suction mechanism (second air flow generator) 76.

It is also difficult for material to enter (become stuck in) the recesses Cf of the second roller 651 d, and the second roller 651 d is therefore driven without material sticking to its surface.

Note that a side seal 690 that contacts the mesh belt 72 is disposed to the side walls 600 c other than the first wall 600 a and second wall 600 b of the first housing 600. The side seal 690 is also a pile seal, is configured like the pile seals described above, and further description thereof is omitted (see FIG. 11B).

The seal structure of the suction mechanism (second air flow generator) is described next. As shown in FIG. 11A, the sheet manufacturing apparatus 100 has a conveyor 700 including a mesh member (mesh belt 72) that conveys the web W, and a suction device (suction mechanism (second air flow generator) 76) that suctions the material including fiber onto the mesh belt 72. The suction mechanism 76 has a second housing 760 that defines the suction area. A third roller 652 d that contacts the mesh belt 72 is disposed to a position opposite the first roller 650 d with the mesh belt 72 therebetween. A third seal 630 disposed to the second housing 760 contacts the outside surface P of the third roller 652 d.

The third seal 630 is disposed to a side wall 760 a on one side of the second housing 760 (downstream in the conveyance direction of the web W), and contacts the outside surface F of the third roller 652 d. The side wall 760 a includes the outside surface, inside surface, and end (the surface facing the mesh belt 72) of the second housing 760. Note that the third seal 630 in this embodiment of the invention is disposed to the outside surface of the side wall 760 a.

The third roller 652 is disposed with its axis of rotation in the direction transverse to the conveyance direction of the web W (widthwise to the web w). The length of the third roller 652 d is the same as the width of the first roller 650 d. The third roller 652 is a follower roller that rotates on its axis of rotation (clockwise in FIG. 11A) in conjunction with movement of the mesh belt 72.

The third roller 652 d is disposed with its axis of rotation in a fixed position to contact the inside surface 72 b of the mesh belt 72. As a result, even if a load is applied in the direction of gravity, the first roller 650 d is supported by the third roller 652 d through the web W and mesh belt 72. The position of the mesh belt 72 is also limited by the third roller 652 d. Therefore, the mesh belt 72 is supported with the accumulation surface of the mesh belt 72 held in a substantially horizontal position without sagging down due to pressure from the first roller 650 d or gravity.

Round recesses Cf are disposed to the outside surface F of the third roller 652 d. The recesses Cf disposed to the outside surface F of the third roller 652 d are the same as the recesses Cf on the first roller 650 d, and further description thereof is omitted (see FIG. 12A and FIG. 12B). The configuration of the third seal 630 is also the same as the configuration of the first seal 610, and further description thereof is omitted. In addition, contact between the third seal 630 and third roller 652 d is also the same as described above, and further description thereof is omitted (see FIG. 13A and FIG. 13B). This configuration substantially seals the second housing 760 and improves the suction performance of the suction mechanism 76.

Operation in the area around the third roller is described next. FIG. 14B schematically illustrates operation in the area around the third roller. When driving the sheet manufacturing apparatus 100, material including fiber from the opening in the drum 61 accumulates on the mesh belt 72. The accumulated material (web W) is conveyed by movement of the mesh belt 72. At this time, the third roller 652 d also turns in contact with the mesh belt 72 (clockwise in FIG. 11A and FIG. 14B). Material forming the web W may also stick to the outside surface F of the third roller 652 d at this time.

Note that because round recesses Cf are formed on the outside surface F of the third roller 652 d in this embodiment of the invention and there are no burrs or sharp parts, there is substantially no catching and sticking of material on the outside surface F of the third roller 652 d.

In this event, the clinging material is held by the recesses Cf formed on the outside surface F of the third roller 652 d and moves rotationally in conjunction with rotation of the third roller 652 d. In addition, in the area where the third seal 630 and third roller 652 d touch, the distal ends of the fibers H of the third seal 630 curve in the direction of rotation of the third roller 652 d due to friction with the recesses Cf of the third roller 652 d (the distal ends of the fibers H bend up in FIG. 14B). As a result, material clinging to the third roller 652 d is easily conveyed in the direction the distal ends of the fibers H of the third seal 630 bend. The material clinging to the third roller 652 d is held by the recesses Cf, and passes through the area of contact between the third seal 630 and third roller 652 d without being wiped off by the third seal 630. As a result, material clumping (agglomerating) near the area of contact between the third seal 630 and third roller 652 d can be prevented. In addition, the material clinging to the third roller 652 d passes the third seal 630, adheres to (or is pulled by) the mesh belt 72, and is conveyed in the direction of rotation of the mesh belt 72. The material sticking to the mesh belt 72 is suctioned by the suction mechanism 76.

It is also difficult for material to become stuck in the recesses Cf of the third roller 652 d, and the third roller 652 d is therefore driven without material sticking to its surface.

A fourth roller 653 d that contacts the mesh belt 72 is disposed to a position opposite the second roller 651 d with the mesh belt 72 therebetween. A fourth seal 640 that contacts the outside surface F of the fourth roller 653 d is also disposed to the second housing 760.

The fourth seal 640 is disposed to a side wall 760 b opposite (on the upstream side in the conveyance direction of the web W) side wall 760 a of the second housing 760, and contacts the outside surface F of the fourth roller 653 d. The side wall 760 b includes the outside surface, inside surface, and end (the surface facing the mesh belt 72) of the second housing 760. Note that the fourth seal 640 in this embodiment of the invention is disposed to the outside surface of the side wall 760 b.

The fourth roller 653 d is disposed with its axis of rotation in the direction transverse to the conveyance direction of the web W (widthwise to the web W). The length of the fourth roller 653 d is the same as the width of the second roller 651 d. The fourth roller 653 d is a follower roller that rotates on its axis of rotation (clockwise in FIG. 11A) in conjunction with movement of the mesh belt 72.

The fourth roller 653 d is disposed with its axis of rotation in a fixed position so that the fourth roller 653 d contacts the inside surface 72 b of the mesh belt 72. As a result, even if a load is applied in the direction of gravity, the second roller 651 d is supported by the fourth roller 653 d through the mesh belt 72. The position of the mesh belt 72 is also limited by the fourth roller 653 d. Therefore, the mesh belt 72 is supported with the accumulation surface of the mesh belt 72 held in a substantially horizontal position without sagging down due to pressure from the second roller 651 d or gravity.

Round recesses Cf are disposed to the outside surface F of the fourth roller 653 d. The recesses Cf formed on the outside surface F of the fourth roller 653 d are the same as the recesses Cf on the first roller 650 d, and further description thereof is omitted (see FIG. 12A and FIG. 12B). The configuration of the fourth seal 640 is also the same as the configuration of the first seal 610, and further description thereof is omitted. In addition, contact between the fourth seal 640 and fourth roller 653 d is also the same as described above, and further description thereof is omitted (see FIG. 13A and FIG. 13B). This configuration substantially seals the second housing 760 and improves the suction performance of the suction mechanism 76.

Operation in the area around the fourth roller is described next. When driving the sheet manufacturing apparatus 100, material including fiber from the opening in the drum 61 accumulates on the mesh belt 72. The accumulated material (web W) is conveyed by movement of the mesh belt 72. At this time, the fourth roller 653 d also turns in contact with the mesh belt 72 (clockwise in FIG. 11A). Material forming the web W may also stick to the outside surface F of the fourth roller 653 d at this time.

Note that because round recesses Cf are formed on the outside surface F of the fourth roller 653 d in this embodiment of the invention and there are no burrs or sharp parts, there is substantially no catching and sticking of material on the outside surface F of the fourth roller 653 d.

In this event, the clinging material is held by the recesses Cf formed on the outside surface F of the fourth roller 653 d and moves rotationally in conjunction with rotation of the fourth roller 653 d. In addition, in the area where the fourth seal 640 and fourth roller 653 d touch, the distal ends of the fibers H of the fourth seal 640 curve in the direction of rotation of the fourth roller 653 d due to friction with the recesses Cf of the fourth roller 653 d (the distal ends of the fibers H bend down in FIG. 11A). As a result, the material clinging to the fourth roller 653 d is easily conveyed in the direction the distal ends of the fibers H of the fourth seal 640 bend. The material clinging to the fourth roller 653 d is held by the recesses Cf, and passes through the area of contact between the fourth seal 640 and fourth roller 653 d without being wiped off by the fourth seal 640. As a result, material clumping (agglomerating) near the area of contact between the fourth seal 640 and fourth roller 653 d can be prevented. In addition, the material clinging to the fourth roller 653 d passes the fourth seal 640, adheres to (or is pulled by) the mesh belt 72, and is conveyed in the direction of rotation of the mesh belt 72. The material sticking to the mesh belt 72 is suctioned by the suction mechanism 76.

It is also difficult for material to become stuck in the recesses Cf of the fourth roller 653 d, and the fourth roller 653 d is therefore driven without material sticking to its surface.

Effects of this embodiment are described below.

Round recesses Cf are disposed to the outside surface F of the first roller 650 d. As a result, material (fiber or resin, for example) catching on the outside surface F of the first roller 650 d and sticking or adhering thereto can be reduced.

A first seal 610 is also disposed touching the outside surface F. As a result, material clinging to the outside surface F of the first roller 650 d passes the first seal 610 and is conveyed forward without being removed by the first seal 610. Therefore, clumps of material forming in the area where the first seal 610 and first roller 650 d are in contact with each other, and near the border to this contact area, is suppressed, and sheets of consistent quality can be produced.

Note that the same effect achieved by the first roller 650 d and first seal 610 can also be achieved with the second, third, and fourth roller 651 d, 652 d, 653 d, and the second, third, and fourth seal 620, 630, 640.

Embodiment 8

A sheet manufacturing apparatus according to an eighth embodiment of the invention is described next. Note that the basic configuration of a sheet manufacturing apparatus is the same as the configuration of the seventh embodiment, and further description thereof is omitted. FIG. 15A schematically illustrates the configuration of an air-laying device. FIG. 15B schematically illustrates operation around a first roller in this embodiment of the invention, and FIG. 15C schematically illustrates operation around a third roller according to this embodiment of the invention. Note that the configuration of the wetting device is omitted in FIG. 15A.

As shown in FIG. 15A, a sheet manufacturing apparatus 100A according to this embodiment has a removal device 800 that contacts the outside surface F of the first roller 650 d and removes material sticking to the outside surface F of the first roller 650 d. Note that the configuration of the first roller 650 d is the same as the configuration in the seventh embodiment of the invention, and further description thereof is omitted.

The removal device 800 in this example is a cleaning brush, and functions to scrape material sticking (accumulated) in the round recesses Cf in the outside surface F of the first roller 650 d and remove such material from the outside surface F of the first roller 650 d.

The removal device 800 has a base 801 and numerous fibers 802 planted densely on one side of the base 801. The fibers 802 are made of a material such as nylon 6 or electrically conductive nylon, and are harder and thicker than the fibers H of the first seal 610. The diameter of the fibers 802 is less than the width D of the recesses Cf, and is, for example, approximately 0.1 mm to 0.5 ms. In addition, the density (distance between fibers) of the fibers 802 of the removal device 800 is coarser than the fibers H of the first seal 610.

The removal device 800 has a length equal to the width dimension of the first roller 650 d in the axial direction. As a result, the removal device 800 can easily contact the entire outside surface F of the first roller 650 d.

As shown in FIG. 15B, the removal device 800 is disposed on the upstream side of the first seal 610 in the direction of rotation of the first roller 650 d. The removal device 800 is disposed so that the distal ends of the fibers 802 face the downstream side of the first roller 650 d in the direction of rotation, and the fibers 802 contact the outside surface F (recesses Cf) at an angle from above the first roller 650 d. Note that the length L from the crests of the first roller 650 d to the distal ends of the fibers 802 is approximately from ⅙ to ⅕ of the diameter of the first roller 650 d. Furthermore, as shown in FIG. 15B, the removal device 800 is disposed to apply a load of approximately 1 N horizontally (in the direction of the arrow in FIG. 15B) to the first roller 650 d.

Operation in the area around the first roller 650 d is described next. As shown in FIG. 15B, when driving the sheet manufacturing apparatus 100A, material including fiber from the opening in the drum 61 accumulates on the mesh belt 72. The accumulated material (web W) is conveyed by movement of the mesh belt 72. At this time, the first roller 650 d also turns in contact with the web W (counterclockwise in FIG. 15A and FIG. 15A). Material forming the web W may also stick to the outside surface F of the first roller 650 d at this time.

Note that because round recesses Cf are formed on the outside surface F of the first roller 650 d in this embodiment of the invention and there are no burrs or sharp parts, there is substantially no catching and sticking of material on the outside surface F of the first roller 650 d.

Sticking material is held by the recesses Cf formed on the outside surface F of the first roller 650 d and moves rotationally in conjunction with rotation of the first roller 650 d.

In the area where the removal device 800 contacts the first roller 650 d, the distal ends of the fibers 802 of the removal device 800 enter the recesses Cf, and material sticking in the recesses Cf is scraped out. The material that is scraped out drops down and sticks to the web W. Note that the removal device 800 can remove not only material sticking in the recesses Cf, but also material sticking to places other than inside the recesses Cf.

Next, in the area where the first seal 610 and first roller 650 d touch, the distal ends of the fibers H of the first seal 610 curve in the direction of rotation of the first roller 650 d due to friction with the recesses Cf of the first roller 650 d (the distal ends of the fibers H bend down in FIG. 15B). As a result, the material clinging to the first roller 650 d is easily conveyed in the direction the distal ends of the fibers H of the first seal 610 bend.

Note that material that could not be completely removed by the removal device 800 and sticks to the first roller 650 d is held in the recesses Cf and passes through the area of contact between the first seal 610 and first roller 650 d without being wiped off by the first seal 610. As a result, material clumping (agglomerating) near the area of contact between the first seal 610 and first roller 650 d can be prevented. In addition, the material clinging to the first roller 650 d passes the first seal 610, contacts and adheres to the web W, and is conveyed downstream in the conveyance direction of the web W.

In addition, because resin does not enter and stick in the recesses Cf of the first roller 650 d, the first roller 650 d drives rotationally without material sticking to its outside surface F.

Note that as shown in FIG. 15A, in addition to the first roller 650 d, a removal device 800 may be applied to the second, third, and fourth roller 651 d, 652 d, 653 d. FIG. 15C illustrates applying a removal device 800 to the third roller 652 d.

In this case, as shown in FIG. 15C, the removal device 800 is disposed on the upstream side of the third seal 630 in the direction of rotation of the third roller 652 d. The removal device 800 is disposed so that the distal ends of the fibers 802 face the downstream side of the third roller 652 d in the direction of rotation, and the fibers 802 contact the outside surface F (recesses Cf) at an angle from below the third roller 652 d. Note that the length L from the crests of the third roller 652 d to the distal ends of the fibers 802 is approximately from ⅙ to ⅕ of the diameter of the third roller 652 d. Furthermore, the removal device 800 is disposed to apply a load of approximately 1 N horizontally to the third roller 652 d.

Note that a receiver for capturing material removed by the removal device 800 may be disposed below the removal device 800. This can prevent dispersion of the material.

Operation in the area around the third roller 652 d is described next. As shown in FIG. 15C, when driving the sheet manufacturing apparatus 100A, material including fiber from the opening in the drum 61 accumulates on the mesh belt 72. The accumulated material (web W) is conveyed by movement of the mesh belt 72. At this time, the third roller 652 d also turns in contact with the mesh belt 72 (clockwise in FIG. 15A and FIG. 15C). Material forming the web W may also stick to the outside surface F of the third roller 652 d at this time.

Note that because round recesses Cf are formed on the outside surface F of the third roller 652 d in this embodiment of the invention and there are no burrs or sharp parts, there is substantially no catching and sticking of material on the outside surface F of the third roller 652 d.

Sticking material is held by the recesses Cf formed on the outside surface F of the third roller 652 d and moves rotationally in conjunction with rotation of the third roller 652 d.

In the area where the removal device 800 contacts the third roller 652 d, the fibers 802 of the removal device 800 enter the recesses Cf, and material sticking in the recesses Cf is scraped out. The material that is scraped out drops down and is captured by the receiver, for example. Note that the removal device 800 removes not only material sticking in the recesses Cf, but also material sticking to the third roller 652 d other than inside the recesses Cf.

Next, in the area where the third seal 630 and third roller 652 d touch, the distal ends of the fibers H of the third seal 630 curve in the direction of rotation of the third roller 652 d due to friction with the recesses Cf of the third roller 652 d (the distal ends of the fibers H bend up in FIG. 15C). As a result, the material clinging to the third roller 652 d is easily conveyed in the direction the distal ends of the fibers H of the third seal 630 bend.

Note that material that could not be removed by the removal device 800 and sticks to the third roller 652 d is held in the recesses Cf and passes through the area of contact between the third seal 630 and third roller 652 d without being wiped off by the third seal 630. As a result, material clumping (agglomerating) near the area of contact between the third seal 630 and third roller 652 d can be prevented. In addition, the material clinging to the third roller 652 d passes the third seal 630, adheres to (or is caught by) the mesh belt 72, and is conveyed in the direction the mesh belt 72 turns. Material sticking to the mesh belt 72 is then suctioned by the suction mechanism 76.

In addition, because resin does not enter and stick in the recesses Cf of the third roller 652 d, the third roller 652 d drives rotationally without material sticking to its outside surface F.

Note that a removal device 800 may be similarly applied to the second roller 651 d and fourth roller 653 d.

Effects of this embodiment are described below.

Material sticking in the recesses Cf of the first roller 650 d is scraped out by the removal device 800. As a result, sticking of material to the first roller 650 d is reduced, and material adhering to the first roller 650 d can be suppressed.

Embodiment 9

A sheet manufacturing apparatus according to a ninth embodiment of the invention is described next. Note that because the basic configuration of a sheet manufacturing apparatus is the same as the configuration of the seventh embodiment, further description thereof is omitted, and configurations that differ, specifically the configuration of another removal device that differs from the configuration of the removal device according to the eighth embodiment of the invention, are described below. FIG. 16 is an external view illustrating the configuration around a first roller in this embodiment of the invention.

As shown in FIG. 16, the removal device 810 according to this embodiment is a brush roller, and includes a roller member 811, and fibers 812 planted in the outside surface of the roller member 811. The roller member 811 is connected to a drive motor (not shown in the figure), and can turn on its axis. In this embodiment of the invention the removal device 810 drives rotationally in the same direction of rotation as the first roller 650 d (counterclockwise in FIG. 16). The fibers 812 are made of a material such as nylon 6 or electrically conductive nylon, are harder than the fibers H of the first seal 610, and the diameter of the fibers 812 (approximately 0.1 mm to 0.5 am) is greater (thicker) than the diameter of the fibers H. In addition, the density of the fibers 812 of the removal device 810 is coarser than the first seal 610.

The removal device 810 has a length equal to the width dimension of the first roller 650 d in the axial direction. As a result, the removal device 810 can easily contact the entire outside surface F of the first roller 650 d.

The removal device 810 is disposed on the upstream side of the first seal 610 in the direction of rotation of the first roller 650 d. The distal ends of the fibers 812 of the removal device 810 are disposed in contact with the outside surface F of the first roller 650 d.

Operation in the area around the first roller 650 d is described next. As shown in FIG. 16, when driving the sheet manufacturing apparatus 100A, material including fiber from the opening in the drum 61 accumulates on the mesh belt 72. The accumulated material (web W) is conveyed by movement of the mesh belt 72. At this time, the first roller 650 d also turns in contact with the web W (counterclockwise in FIG. 11A and FIG. 16). Material forming the web W may also stick to the outside surface F of the first roller 650 d at this time.

Note that because round recesses Cf are formed on the outside surface F of the first roller 650 d in this embodiment of the invention and there are no burrs or sharp parts, there is substantially no catching and sticking of material on the outside surface F of the first roller 650 d.

Sticking material is held by the recesses Cf formed on the outside surface F of the first roller 650 d and moves rotationally in conjunction with rotation of the first roller 650 d.

In the area where the removal device 810 contacts the first roller 650 d, the fibers 812 of the removal device 810 enter the recesses Cf, and material sticking in the recesses Cf is scraped out. The material that is scraped out drops down and sticks to the web W. Note that the removal device 810 can remove not only material sticking in the recesses Cf, but also material sticking to places other than inside the recesses Cf.

Next, in the area where the first seal 610 and first roller 650 d touch, the distal ends of the fibers H of the first seal 610 curve in the direction of rotation of the first roller 650 d due to friction with the recesses Cf of the first roller 650 d (the distal ends of the fibers H bend down in FIG. 16). As a result, the material clinging to the first roller 650 d is easily conveyed in the direction the distal ends of the fibers H of the first seal 610 bend.

Note that material that could not be completely removed by the removal device 810 and sticks to the first roller 650 d is held in the recesses Cf and passes through the area of contact between the first seal 610 and first roller 650 d without being wiped off by the first seal 610. As a result, material clumping (agglomerating) near the area of contact between the first seal 610 and first roller 650 d can be prevented. In addition, the material clinging to the first roller 650 d passes the first seal 610, contacts and adheres to the web W, and is conveyed downstream in the conveyance direction of the web W.

In addition, because it is difficult for material to get into the round recesses Cf of the first roller 650 d, the first roller 650 d drives rotationally without material sticking to its outside surface F.

Effects of this embodiment are described below.

Material sticking in the recesses Cf of the first roller 650 d is scraped out by the removal device 810. In addition, because the removal device 810 is a brush roller, the contact pressure or contact position of the fibers 812 against the outside surface F of the first roller 650 d can be easily adjusted by controlling the rotational speed of the roller member 811. As a result, sticking of material to the first roller 650 d can be desirably reduced.

Note that the removal device 810 described above may be applied to the second, third, and fourth roller 651 d, 652 d, 653 d in addition to the first roller 650 d.

Furthermore, the seventh to ninth embodiments describe configurations applying the first roller 650 d and other components to the air-laying device, but the first roller 650 d and other components may also be applied to the wetting device 78. The removal devices 800, 810 according to the eighth and ninth embodiments may also be applied to the wetting device 78.

The first roller 650 d and other components may also be applied to the classifier 40. The removal devices 800, 810 according to the eighth and ninth embodiments may also be applied to the classifier 40.

Embodiment 10

A sheet manufacturing apparatus according to a tenth embodiment of the invention is described next. Note that the basic configuration of this sheet manufacturing apparatus is the same as the configuration of the first embodiment, further description thereof is omitted, and configurations that differ, specifically the seal configuration of the suction device, are described below. More specifically, the configuration of the suction mechanism 76 corresponding to the air-laying device 60 is described. FIG. 17A is a section view schematically illustrating the configuration around the suction device of the air-laying device, FIG. 17B is a plan view illustrating the configuration around the suction device of the air-laying device, and FIG. 17C is an oblique view illustrating part of the configuration around the suction device of the air-laying device. FIG. 18 is an oblique view illustrating part of the configuration around the air-laying device. Note that FIG. 17A illustrates the configuration without showing the wetting device.

As shown in FIG. 17A and FIG. 17B, the suction mechanism 76 has a first housing 1760 that defines the suction area As on the back side 1072 b of the accumulation surface 1072 a of the mesh belt 72 on which material accumulates as a web W. A first roller 1650 is disposed in contact with the back side 1072 b of the mesh belt 72 outside the first housing 1760, and a first seal 1610 is disposed to the first housing 1760 in contact with the outside surface F of the first roller 1650.

The first housing 1760 is a frame with side walls, and is hollow inside. The top of the first housing 1760 does not have a wall member, and instead is an opening 1761 facing the back side 1072 b of the mesh belt 72. Note that the area of the opening 1761 corresponds to the auction area As. In this embodiment of the invention, the width of the suction area As (opening 1761) (length L2 corresponding to the width of the web W) is equal to the dimension Wb of the width of the web w (see FIG. 18).

The first roller 1650 is disposed with its axis of rotation in a fixed position so that the first roller 1650 contacts the back side 1072 b of the mesh belt 72. In addition, the first roller 1650 is disposed with its axis of rotation in the direction transverse to the conveyance direction of the web W (widthwise to the web W). Furthermore, first roller 1650 has a length L1 greater than the dimension Mb of the width of the web W (see FIG. 18).

The first roller 1650 is a follower roller that rotates on its axis of rotation (clockwise in FIG. 17A) in conjunction with movement of the mesh belt 72.

The first seal 1610 in this embodiment includes a first seal member 1610 a and a second seal member 1610 b. The first seal member 1610 a and second seal member 1610 b are, for example, pile seals comprising a base FL and numerous fibers H planted densely on the one side of the base FL.

The first seal member 1610 a is disposed with the other side of the base FL of the first seal member 1610 a attached to the outside surface of the side wall 1760 a of the first housing 1760 on the downstream side in the conveyance direction of the web W, and is configured with the distal ends of the fibers H of the first seal member 1610 a in contact with the outside surface F of the first roller 1650.

The first seal member 1610 a of the first seal 1610 is disposed with at least part thereof not touching the back side 1072 b of the mesh belt 72. As shown in FIG. 17A, in this embodiment the first seal member 1610 a is disposed so that there is a gap between the entire top side of the first seal member 1610 a and the back side 1072 b of the mesh belt 72. In other words, as shown in FIG. 17B, in the area of the first seal member 1610 a corresponding to the width of the suction area As (length L2 corresponding to the width of the web W), the first seal member 1610 a is disposed separated and not touching the back side 1072 b of the mesh belt 72. As a result, the gap between the first housing 1760 and the first roller 1650 can be sealed while also reducing the load on the mesh belt 72. Note that the gap between the first seal member 1610 a and the back side 1072 b of the mesh belt 72 can be set appropriately by the configuration of the first seal 1610 and the configuration of the first roller 1650.

Outside the suction area As, the second seal member 1610 b of the first seal 1610 contacts back side 1072 b of the mesh belt 72, and contacts the end 1650 a of the first roller 1650. As shown in FIG. 17B and FIG. 17C, in this embodiment the second seal member 1610 b is disposed so that the distal ends of the fibers H contact part of the end 1650 a of the first roller 1650. In addition, the second seal member 1610 b is disposed so that the distal ends of the fibers H contact the first seal member 1610 a. As a result, the gap between the area around the end 1650 a of the first roller 1650 and the mesh belt 72 is substantially sealed. In the space bounded by the first roller 1650, first housing 1760, and mesh belt 72, the second seal member 1610 b can also assure a seal in the area around the end 1650 a of the first roller 1650.

With this configuration, the space bounded by the first roller 1650, first housing 1760, and mesh belt 72 is substantially closed tight (sealed) by the first seal member 1610 a affixed to the first housing 1760 and contacting the first roller 1650, and the second seal member 1610 b in contact with the first seal member 1610 a and the end 1650 a of the first roller 1650. In addition, because the first seal member 1610 a does not contact the back side 1072 b of the mesh belt 72, material does not stick and accumulate in the area between the first seal member 1610 a and the mesh belt 72, and the load on the mesh belt 72 is reduced.

In addition, on the upstream side of the first roller 1650 in the conveyance direction of the web W is disposed a second roller 1651 outside the first housing 1760 and in contact with back side 1072 b of the mesh belt 72. A second seal 1620 is also disposed to the first housing 1760 in contact with the outside surface F of the second roller 1651.

The second roller 1651 is disposed with its axis of rotation in a fixed position so that the second roller 1651 contacts the back side 1072 b of the mesh belt 72. In addition, the second roller 1651 is disposed with its axis of rotation in the direction transverse to the conveyance direction of the web W (widthwise to the web w). Furthermore, second roller 651 has a length L1 greater than the dimension Wb of the width of the web W (see FIG. 18) (the same dimension as the first roller 1650).

The second roller 1651 is a follower roller that rotates on its axis of rotation (clockwise in FIG. 17A) in conjunction with movement of the mesh belt 72.

The second seal 1620 includes a first seal member 1620 a and a second seal member 1620 b. The first seal member 1620 a and second seal member 1620 b are, for example, pile seals configured as described above.

The first seal member 1620 a is disposed with the other side of the base FL attached to the outside surface of the side wall 1760 b opposite side wall 1760 a of the first housing 1760 (on the upstream side in the conveyance direction of the web W), and is configured with the distal ends of the fibers H of the first seal member 1620 a in contact with the outside surface F of the second roller 1651.

The first seal member 1620 a of the second seal 1620 is disposed not touching the back side 1072 b of the mesh belt 72 as described above. As shown in FIG. 17A, in this embodiment the first seal member 1620 a is disposed so that there is a gap between the entire top side of the first seal member 1620 a and the back side 1072 b of the mesh belt 72. As a result, the gap between the first housing 1760 and the second roller 1651 is substantially sealed. As shown in FIG. 17B, in the space bounded by the second roller 1651, the first housing 1760, and the mesh belt 72, the second seal member 1620 b can also assure a seal in the area around the end 1651 a of the second roller 1651.

In addition, outside the suction area As, the second seal member 1620 b of the second seal 1620 contacts back side 1072 b of the mesh belt 72, and contacts the end 1651 a of the second roller 1651. In this embodiment the second seal member 1620 b is disposed so that the distal ends of the fibers H contact part of the end 1651 a of the second roller 1651. In addition, the second seal member 1620 b is disposed so that the distal ends of the fibers H contact the first seal member 1620 a. As a result, the gap between the area around end 1651 a of the second roller 1651 and the mesh belt 72 is substantially sealed.

With this configuration, the space bounded by the second roller 1651, first housing 1760, and mesh belt 72 is substantially closed tight (sealed) by the first seal member 1620 a affixed to the first housing 1760 and contacting the second roller 1651, and the second seal member 1620 b in contact with the first seal member 1620 a and the end 1651 a of the second roller 1651. In addition, because the first seal member 1620 a does not contact the back side 1072 b of the mesh belt 72, material does not stick and accumulate in the area between the first seal member 1620 a and the mesh belt 72, and the load on the mesh belt 72 is reduced.

As shown in FIG. 17A, an air-laying device 60 is disposed on the accumulation surface 1072 a side of the mesh belt 72. The air-laying device 60 includes a foraminous drum 61 (sieve); and a second housing 1600 covering the drum 61.

The drum 61 includes a rotatable cylinder, and numerous holes through which at least material including fiber carried by air passes are formed in the cylinder. The many holes are the same size (area) and are disposed at a uniform spacing. As a result, when passing through the holes, tangled fibers are detangled, and the material passing through the holes accumulates at a uniform thickness and density on the mesh belt 72 (accumulation surface 1072 a). Note that the size of the holes is set desirably according to the size and type of the material that is past. In addition, the holes are not limited to holes formed in punched metal, and may be a metal screen.

The second housing 1600 has a frame 1601, and is hollow inside. The drum 61 is placed inside the frame 1601, and is thereby covered (surrounded) by the second housing 1600. An opening 1602 is disposed instead of a floor panel at the bottom of the second housing 1600. The opening 1602 is disposed facing the opening 1761 of the first housing 1760. As a result, substantially uniform suction can be applied inside the second housing 1600, and material passing through the holes in the drum 61 disposed inside the second housing 1600 can be consistently deposited on the mesh member (mesh belt 72).

Also disposed are a third roller 1652 that contacts the web W conveyed by the mesh belt 72, and a third seal 1630 disposed to the second housing 1600 covering the drum 61 and in contact with the outside surface F of the third roller 1652.

The third roller 1652 is disposed on the downstream side of the second housing 1600 in the conveyance direction of the web W. The third seal 1630 is disposed to the side wall 1600 a on the downstream side of the second housing 1600 in the conveyance direction of the web W. The side wall 1600 a has an outside surface, an inside surface, and an and (the surface facing the mesh belt 72). Note that the third seal 1630 in this embodiment is disposed to the outside surface of the side wall 1600 a.

The third roller 1652, as shown in FIG. 18, is disposed with its axis of rotation in the direction transverse to the conveyance direction of the web W (widthwise to the web W). The third roller 1652 has a length greater than the width dimension (the length widthwise to the web W) of the frame 1601 of the second housing 1600. In other words, the length of the third roller 1652 along the axis of rotation is greater than the dimension Wb of the width of the web W, and is equal to the length L1 of the first roller 1650 along the axis of rotation.

The third roller 1652 is connected to a drive device (not shown in the figure) such as a motor that drives the third roller 1652. By driving the drive device, the third roller 1652 can be turned on its axis of rotation (counterclockwise in FIG. 17A). The drive speed (circumferential speed) of the third roller 1652 is set to be faster than the conveyance speed (speed of travel) of the web W by the mesh belt 72. In other words, the third roller 1652 is configured so that the circumferential speed is greater than the conveyance speed (speed of travel) of the web W by the mesh belt 72. As a result, the web W can be pulled more easily in the conveyance direction, accumulation of the web W and buckling of the web W inside the second housing 1600 are reduced, and the web W can be conveyed stably. Note that the third roller 1652 is disposed so that its axis of rotation is positioned above the maximum height (thickness) of the web W that accumulates upstream in the conveyance direction from the third roller 1652. If the axis of rotation of the third roller 1652 is at a position lower than the maximum height (thickness) of the web W that accumulates upstream in the conveyance direction from the third roller 1652, conveying the top part of the accumulated web W becomes difficult, and the web W can easily accumulate inside the second housing 1600.

The third roller 1652 can move vertically (perpendicularly to the accumulation surface 1072 a of the mesh belt 72, or the thickness of the web W), and is urged down (to the mesh belt 72 side) by an urging member (not shown in the figure).

The third roller 1652 and first roller 1650 are disposed in opposition with the mesh belt 72 therebetween. The first roller 1650 is disposed with its axis of rotation in a fixed position in contact with the back side 1072 b of the mesh belt 72. As a result, even if a load is applied in the direction of gravity, the third roller 1652 is supported by the first roller 1650 through the web W and mesh belt 72. The position of the mesh belt 72 is also limited by the first roller 1650. Therefore, the mesh belt 72 is supported with the accumulation surface 1072 a of the mesh belt 72 held in a substantially horizontal position without sagging down due to pressure from the third roller 1652 or gravity.

A fourth roller 1653 is disposed on the on the upstream side of the third roller 1652 in the conveyance direction of the web W. A sixth seal 1640 that contacts the fourth roller 1653 is disposed to the side wall 1600 b opposite the side wall 1600 a of the second housing 1600 (on the upstream side in the conveyance direction of the web W). The sixth seal 1640 in this embodiment is disposed to the outside surface of the side wall 1600 b. The sixth seal 1640 touches the fourth roller 1653.

The fourth roller 1653, as shown in FIG. 18, is disposed with its axis of rotation in the direction transverse to the conveyance direction of the web W (widthwise to the web W). The fourth roller 1653 has a length greater than the width dimension (the length widthwise to the web W) of the frame 1601 of the second housing 1600. In other words, the length of the fourth roller 1653 along the axis of rotation is greater than the dimension Wb of the width of the web W, and is equal to the length L1 of the second roller 1651 along the axis of rotation.

The fourth roller 1653 is connected to a drive device (not shown in the figure) such as a motor that drives the fourth roller 1653. By driving the drive device, the fourth roller 1653 can be turned on its axis of rotation (counterclockwise in FIG. 18). The drive speed (circumferential speed) of the fourth roller 1653 is set to be faster than the conveyance speed (speed of travel) of the web w by the mesh belt 72. The fourth roller 1653 is disposed to contact the accumulation surface 1072 a of the mesh belt 72.

The fourth roller 1653 and second roller 1651 are disposed in opposition with the mesh belt 72 therebetween. The second roller 1651 is disposed with its axis of rotation in a fixed position in contact with the back side 1072 b of the mesh belt 72. As a result, even if a load is applied in the direction of gravity, the fourth roller 1653 is supported by the second roller 1651 through the web W and mesh belt 72. The position of the mesh belt 72 is also limited by the second roller 1651. Therefore, the mesh belt 72 is supported with the accumulation surface 1072 a held in a substantially horizontal position without sagging down due to pressure from the fourth roller 1653 or gravity.

As shown in FIG. 18, the second housing 1600 that covers the drum 61 also a first wall 1600 c and a second wall 1600 d opposite each other in the axial direction of the drum 61. A fourth seal 1680 that contacts the accumulation surface 1072 a of the mesh belt 72 is disposed to the first wall 1600 c. A fifth seal 1690 that contacts the accumulation surface 1072 a of the mesh belt 72 is disposed to the second wall 1600 d. The fourth and fifth seals 1680, 1690 are pile seals, the configuration of which is as described above.

At least part of the fourth seal 1680 and fifth seal 1690 is disposed opposite the first seal 1610 with the mesh belt 72 therebetween. More specifically, one end P of the fourth seal 1680 (see FIG. 18) and the second seal member 1610 b of the first seal 1610 (see FIG. 17B) are disposed in opposition. In addition, one end P of the fifth seal 1690 and the other second seal member 1610 b of the first seal 1610 are disposed in opposition. In addition, the other end P′ of the fourth seal 1680 (see FIG. 18) and one second seal member 1620 b of the second seal 1620 (see FIG. 17B) are disposed in opposition. In addition, the other end P′ of the fifth seal 1690 and the other second seal member 1620 b of the second seal 1620 are disposed in opposition. As a result, a seal can be assured between the first wall 1600 c and second wall 1600 d of the second housing 1600 and the mesh belt 72.

Effects of this embodiment are described below.

The space bounded by the first roller 1650 and the second roller 1651, and the first housing 1760 and the mesh belt 72, is substantially closed tight (sealed) by the first seal 1610 and first roller 1650, and the second seal 1620 and second roller 1651. As a result, unnecessary suction from other than the second housing 1600 is suppressed, and material past from the opening to the drum 61 can be suctioned consistently. As a result, sheets S with even greater uniformity can be produced.

Because the first seal member 1610 a of the first seal 1610 is separated from and does not contact the back side 1072 b of the mesh belt 72, problems such as material accumulating are reduced, and the load on the mesh belt 72 can be suppressed. Note that the same effect is achieved by the first seal member 1620 a of the second seal 1620.

Furthermore, because the second seal member 1610 b of the first seal 1610 contacts back side 1072 b of the mesh belt 72, and contacts the end 1650 a of the first roller first roller 1650, suction from around the end 1650 a of the first roller 1650 in the space bounded by the first roller 1650, first housing 1760, and mesh belt 72 can be reliably suppressed. Note that the same effect is achieved by the second seal member 1620 b of the second seal 1620.

Embodiment 11

A sheet manufacturing apparatus according to an eleventh embodiment of the invention is described next. Note that the basic configuration of this sheet manufacturing apparatus is the same as the configuration of the tenth embodiment, further description thereof is omitted, and configurations that differ, specifically the configuration of the first seal, are described below. FIG. 19 is an oblique view illustrating part of the configuration around the suction device of the air-laying device according to this embodiment.

As shown in FIG. 19, the first seal 1660 according to this embodiment contacts the back side 1072 b of the mesh belt 72 and the outside surface F of the first roller 1650 outside the area in which the suction area As extends in the conveyance direction of the web W.

More specifically, the first seal 1660 includes a first seal member 1660 a and a second seal member 1660 b. The first seal member 1660 a and the second seal member 1660 b are, for example, pile seals and are configured as described above.

The first seal member 1660 a is disposed with the other side of the base FL of the first seal member 1660 a attached to the outside surface of side wall 1760 a of the first housing 1760, and is configured with the distal ends of the fibers H of the first seal member 1660 a in contact with the outside surface F of the first roller 1650. The first seal member 1660 a is disposed so that there is a gap between the entire top side of the first seal member 1660 a and the back side 1072 b of the mesh belt 72. In other words, in the area of the first seal member 1660 a corresponding to the width of the suction area As (length L2 corresponding to the width of the web W), the first seal member 1660 a is disposed separated and not touching the back side 1072 b of the mesh belt 72. As a result, the gap between the first housing 1760 and the first roller 1650 is substantially sealed.

In addition, the second seal members 1660 b of the first seal 1660 contact the back side 1072 b of the mesh belt 72 and the outside surface F of each end of the first roller 1650 outside the area in which the suction area As extends in the conveyance direction of the web W. In this embodiment of the invention, the distal ends of the fibers H of the second seal member 1660 b are disposed to contact the outside surface F of the first roller 1650. In addition, the second seal members 1660 b are disposed to contact the ends of the first seal member 1660 a. As a result, the second seal members 1660 b can assure a seal around the ends of the first roller 1650 in the space bounded by the first roller 1650, first housing 1760, and mesh belt 72.

Effects of this embodiment are described below.

The space bounded by the first roller 1650, first housing 1760, and mesh belt 72 is substantially closed tight (sealed) by the first seal member 1660 a attached to the first housing 1760 and contacting the first roller 1650, and the second seal members 1660 b contacting the first seal member 1660 a and both ends of the outside surface F of the first roller 1650. Furthermore, because the first seal member 1660 a does not contact the back side 1072 b of the mesh belt 72, material does not stick and collect in the area between the first seal member 1660 a and the mesh belt 72, and the load on the mesh belt 72 is reduced.

Embodiment 12

A sheet manufacturing apparatus according to a twelfth embodiment of the invention is described next. In a sheet manufacturing apparatus according to the tenth and eleventh embodiments of the invention, configurations applying the first seal, for example, to the suction device of the air-laying device are described, but this embodiment of the invention applies the first seal, for example, to the suction device of the wetting device. FIG. 20 schematically illustrates the configuration around the suction device of the wetting device in a twelfth embodiment of the invention. Note that FIG. 20 shows the configuration without the air-laying device.

The wetting device 78 wets the web W deposited by the air-laying device 60. The wetting device 78 includes a first air flow generator 1176 as a suction device with a third housing 1177, generator 1170, and a fourth housing 1172.

The generator 1170 is disposed on the accumulation surface 1072 a side of the mesh belt 72. In FIG. 20, the generator 1170 is disposed outside the area enclosed by the mesh belt 72. The generator 1170 generates fluid droplets or a high humidity gas. The generator 1170 may generate fluid droplets by ultrasonic waves. The generator 1170 may, for example, apply ultrasonic waves at a frequency of 20 kHz to several MHz to fluid (water) to generate minute fluid droplets ranging from several nanometers to several microns. The generator 1170 may also produce steam to generate a high humidity gas. High humidity gas as used here means a gas at greater than or equal to 70% and less than or equal to 100% relative humidity.

The fourth housing 1172 is connected to the generator 1170 through a conduit 1171. The fourth housing 1172 is disposed on the accumulation surface 1072 a side. The fourth housing 1172 is shaped like a box, for example, and has an opening facing the accumulation surface 1072 a of the mesh belt 72. The fourth housing 1172 defines the wetting area for wetting the web w. The wetting device 78 can wet the web W deposited on the accumulation surface 1072 a in the wetting area.

The first air flow generator 1176 is disposed on the back side 1072 b side of the mesh belt 72. In FIG. 20, the first air flow generator 1176 is disposed inside the area surrounded by the mesh belt 72. The first air flow generator 1176 is disposed opposite the fourth housing 1172 with the mesh belt 72 therebetween. The first air flow generator 1176 produces an air flow through the web w in the thickness direction. This air flow is a current intersecting the accumulation surface 1072 a, and in this example is a current in the direction perpendicular to the accumulation surface 1072 a. The wetting device 78 can supply fluid droplets or high humidity gas to the web W by the air flow generated by the first air flow generator 1176. The fluid droplets or high humidity gas are carried through the thickness of the web W by the air flow. The mass of the fluid droplets supplied by the wetting device 78 to the web W is, in this example, greater than or equal to 0.1% and less than or equal to 3% of the mass of the web W per unit volume of the web W. In the example in the figure, the first air flow generator 1176 is a suction device (first suction device) that suctions fluid droplets or high humidity gas generated by the generator 1170 from the back side 1072 b. The first air flow generator 1176 has a third housing 1177 disposed below the mesh belt 72 with an opening facing the back side 1072 b. A vacuum blower that suctions air from inside the third housing 1177 is connected.

A first roller 1650 is disposed in contact with the back side 1072 b of the mesh belt 72 outside the third housing 1177. A first seal 1610 is disposed to the third housing 1177 in contact with the outside surface F of the first roller 1650. The configurations of the first roller 1650 and first seal 1610 are as described in the tenth embodiment, and further description thereof is omitted.

In addition, on the upstream side of the first roller 1650 in the conveyance direction of the web W is disposed a second roller 1651 outside the third housing 1177 and in contact with back side 1072 b of the mesh belt 72. A second seal 1620 is also disposed to the third housing 1177 in contact with the outside surface F of the second roller 1651. The configurations of the second roller 1651 and the second seal 1620 are as described in the tenth embodiment, and further description thereof is omitted.

Also disposed is a third roller 1652 that contacts the web W conveyed by the mesh belt 72. A third seal 1630 is disposed to the side wall 1172 a on the downstream side of the fourth housing 1172 in the conveyance direction of the web W, and contacts the outside surface F of the third roller 1652. The configurations of the third roller 1652 and the third seal 1630 are as described in the tenth embodiment, and further description thereof is omitted. The third roller 1652 is disposed to a position opposite the first roller 1650 with the mesh belt 72 therebetween. Because the first roller 1650 is disposed with its axis of rotation in a fixed position so that the first roller 1650 contacts the back side 1072 b of the mesh belt 72, the third roller 1652 is supported by the first roller 1650 through the web W and mesh belt 72 even if a load is applied in the direction of gravity. The position of the mesh belt 72 is also limited by the first roller 1650, and the mesh belt 72 is supported with the accumulation surface 1072 a held in a substantially horizontal position without sagging down due to pressure from the third roller 1652 or gravity.

A fourth roller 1653 is disposed on the on the upstream side of the third roller 1652 in the conveyance direction of the web W. A sixth seal 1640 that contacts the fourth roller 1653 is disposed to the side wall 1172 b opposite the side wall 1172 a of the fourth housing 1172 (on the upstream side in the conveyance direction of the web W). The sixth seal 1640 is disposed to the outside surface of the side wall 1172 b. The sixth seal 1640 touches the fourth roller 1653. The configurations of the fourth roller 1653 and sixth seal 1640 are as described in the tenth embodiment, and further description thereof is omitted. The fourth roller 1653 is disposed opposite the second roller 1651 with the mesh belt 72 therebetween. Because the second roller 1651 is disposed with its axis of rotation in a fixed position in contact with the back side 1072 b of the mesh belt 72, the fourth roller 1653 is supported by the second roller 1651 through the web W and mesh belt 72 even if a load is applied in the direction of gravity. The position of the mesh belt 72 is also limited by the second roller 1651, and the mesh belt 72 is supported with the accumulation surface 1072 a held in a substantially horizontal position without sagging down due to pressure from the fourth roller 1653 or gravity.

Effects of this embodiment are described below.

The space bounded by the first roller 1650 and the second roller 1651, and the third housing 1177 and the mesh belt 72, is substantially closed tight (sealed) by the first seal 1610 and first roller 1650, and the second seal 1620 and second roller 1651. As a result, unnecessary suction from other than the fourth housing 1172 is suppressed, and the moisture content of the web W can be consistently adjusted.

Furthermore, because the first seal member 1610 a of the first seal 1610 is separated from and does not contact the back side 1072 b of the mesh belt 72, problems such as material accumulating are reduced, and the load on the mesh belt 72 can be suppressed. Note that the same effect is achieved by the first seal member 1620 a of the second seal 1620. Furthermore, material sticking to the first seal 1610 is suppressed, and the load on the mesh belt 72 is reduced. In addition, the area around the ends of the first roller 1650 in the space bounded by the first roller 1650, third housing 1177, and mesh belt 72 can be reliably sealed by the second seal member 1610 b of the first seal 1610. Note that the same effect can be achieved by the second seal member 1620 b of the second seal 1620.

Embodiment 13

A sheet manufacturing apparatus according to a thirteenth embodiment of the invention is described next. In a sheet manufacturing apparatus according to the tenth and eleventh embodiments of the invention, configurations applying the first seal, for example, to the suction device of the air-laying device are described, but this embodiment of the invention applies the first seal, for example, to the suction device of the classifier. FIG. 21 schematically illustrates the configuration around the suction device of the classifier.

In addition, as shown in FIG. 21, a suction device (suction mechanism) 48 is disposed on the back 1046 b side of the mesh belt 46. The suction device 48 has a fifth housing 1480 disposed below the mesh belt 46 with an opening 1481 facing the back 1046 b. A sixth housing 1400 is also disposed to a position opposite the fifth housing 1480 with the mesh belt 46 therebetween. The sixth housing 1400 has an opening 1404 facing the accumulation surface 1046 a of the mesh belt 46. The sieve 41 is disposed inside the sixth housing 1400.

A first roller 1650 is disposed in contact with the back 1046 b of the mesh belt 46 outside the fifth housing 1480. A first seal 1610 is disposed to the fifth housing 1480 in contact with the outside surface F of the first roller 1650. The configuration of the first roller 1650 and the first seal 1610 is the same as in the tenth embodiment, and further description thereof is omitted.

In addition, on the upstream side of the first roller 1650 in the conveyance direction of the web V is disposed a second roller 1651 outside the fifth housing 1480 and in contact with back 1046 b of the mesh belt 46. A second seal 1620 is also disposed to the fifth housing 1480 in contact with the outside surface F of the second roller 1651. The configuration of the second roller 1651 and the second seal 1620 is the same as in the tenth embodiment, and further description thereof is omitted.

A third roller 1652 is provided in contact with the web V conveyed by the mesh belt 46. A third seal 1630 is disposed in contact with the outside surface F of the third roller 1652 on the downstream side of the sixth housing 1400 in the conveyance direction web V. Note that the configuration of the third roller 1652 and the third seal 1630 is the same as in the tenth embodiment, and further description thereof is omitted. The third roller 1652 is disposed to a position opposite the first roller 1650 with the mesh belt 46 therebetween. Because the first roller 1650 is disposed with its axis of rotation in a fixed position to contact the back 1046 b of the mesh belt 46, the third roller 1652 is supported by the first roller 1650 through the web V and mesh belt 46 even if a load is applied in the direction of gravity. The position of the mesh belt 46 is also limited by the first roller 1650, and the mesh belt 46 is supported with the accumulation surface 1046 a held in a substantially horizontal position without sagging down due to pressure from the third roller 1652 or gravity.

A fourth roller 1653 is disposed on the on the upstream side of the third roller 1652 in the conveyance direction of the web V. A sixth seal 1640 that contacts the fourth roller 1653 is disposed to the side wall 1400 b opposite side wall 1400 a of the sixth housing 1400 (on the upstream side in the conveyance direction of the web W). The sixth seal 1640 is disposed to the outside surface of the side wall 1400 b. The sixth seal 1640 touches the fourth roller 1653. The configuration of the fourth roller 1653 and the sixth seal 1640 is the same as in the tenth embodiment, and further description thereof is omitted. The fourth roller 1653 is disposed to a position opposite the second roller 1651 with the mesh belt 46 therebetween. Because the second roller 1651 is disposed with its axis of rotation in a fixed position to contact the back 1046 b of the mesh belt 46, the fourth roller 1653 is supported by the second roller 1651 through the mesh belt 46 even if a load is applied in the direction of gravity. As a result, the position of the mesh belt 46 is also limited by the second roller 1651, and the mesh belt 46 is supported with the accumulation surface 1046 a held in a substantially horizontal position without sagging down due to pressure from the fourth roller 1653 or gravity.

Effects of this embodiment are described below.

The space bounded by the first roller 1650 and the second roller 1651, the fifth housing 1480 and the mesh belt 46, is substantially closed tight (sealed) by the first seal 1610 and first roller 1650, and the second seal 1620 and second roller 1651. As a result, unnecessary suction from other than the sixth housing 1400 is suppressed, and material past from the opening to the sieve 41 can be suctioned consistently.

Because the first seal member 1610 a of the first seal 1610 is separated from and does not contact the back 1046 b of the mesh belt 46, problems such as material accumulating are reduced, and the load on the mesh belt 46 can be suppressed. Note that the same effect is achieved by the first seal member 1620 a of the second seal 1620. Material sticking to the first seal 1610 is also suppressed, and the load on the mesh belt 46 is reduced. In addition, in the space bounded by the first roller 1650, fifth housing 1480, and mesh belt 46, the ends of the first roller 1650 can be substantially closed tight (sealed) by the second seal member 1610 b of the first seal 1610. Note that the same effect is achieved by the second seal member 1620 b of the second seal 1620.

The present invention is not limited to the foregoing embodiment, and the foregoing embodiment can be modified and improved in many ways. Examples of some variations are described below. These examples may also be used in combination.

(Variation 1) The second seal member 1610 b of the first seal 1610 in the tenth embodiment of the invention is a pile seal comprising a base FL and numerous fibers H planted densely on one side of the base FL, but the invention is not so limited. FIG. 22 is a partial oblique view illustrating the configuration of a first seal according to this variation of the invention. As shown in FIG. 22, in this example the first seal 1670 includes a first seal member 1670 a and a second seal member 1670 b. The configuration of the first seal member 1670 a is the same as the configuration described in the tenth embodiment. The second seal member 1670 b has a base FL affixed to a receiver G, and numerous fibers H planted densely on the opposite side of the base FL as the side affixed to the receiver G. The receiver G is a plastic member made from POM (polyacetal), for example. The second seal member 1670 b is disposed with the receiver G in contact with the first seal member 1670 a, and the fibers H touching the end 1650 a of the first roller first roller 1650. By providing a receiver G to the second seal member 1670 b in this example, a general purpose pile seal with relatively short fibers H can be used.

(Variation 2) The first seal 1610 according to the tenth embodiment is used in the twelfth and thirteenth embodiments, but the invention is not so limited and the first seal 1660 according to the eleventh embodiment may be used instead of first seal 1610. The configuration of the first seal 1660 may also be used for the second, third, and sixth seals 1620, 1630, 1640. The same effects described above can also be achieved in this case.

(Variation 3) The fourth and fifth seal 1680, 1690 of the tenth embodiment may also be applied to the twelfth and thirteenth embodiments. The same effects described above can also be achieved in this case.

REFERENCE SIGNS LIST

-   41 drum unit -   46 mesh belt -   47 tension roller -   61 drum unit -   72 mesh belt -   74 tension roller -   76 suction mechanism -   78 wetting device -   100, 100A, 100B sheet manufacturing apparatus -   172 third housing -   177 fourth housing -   400 fifth housing -   460 conveyor -   480 sixth housing -   600 first housing -   610 first seal -   620 second seal -   630 third seal -   640 fourth seal -   650, 650 a, 650 a′, 650 b, 650 c, 650 d first roller -   651, 651 a, 651 a′, 651 b, 651 c, 651 d second roller -   652, 652 a, 652 a′, 652 b, 652 c, 652 d third roller -   653, 653 a, 653 a′, 653 b, 653 c, 653 d fourth roller -   700 conveyor -   760 second housing -   800, 810 removal device -   801 base -   802, 812 fiber -   811 roller member -   1046 a accumulation surface -   1046 b back -   1072 a accumulation surface -   1072 b back -   1172 fourth housing -   1177 third housing -   1400 sixth housing -   1480 fifth housing -   1600 second housing -   1610 first seal -   1610 a first seal member -   1610 b second seal member -   1620 second seal -   1620 a first seal member -   1620 b second seal member -   1630 third seal -   1640 sixth seal -   1650 first roller -   1650 a end -   1651 second roller -   1651 a end -   1652 third roller -   1653 fourth roller -   1680 fourth seal -   1690 fifth seal -   1760 first housing -   Nf asperities -   F outside surface -   T channels -   Cf round recesses 

1. A sheet manufacturing apparatus comprising: a drum with a plurality of holes; a first housing covering the drum; a conveyor on which material including fiber that has passed through the holes accumulates as a web, and which conveys the accumulated web; a first roller that is a first roller disposed to contact the web conveyed by the conveyor, and has asperities on an outside surface; and a first seal disposed to a first wall of the first housing to contact an outside surface of the first roller.
 2. The sheet manufacturing apparatus according to claim 1, wherein: the asperities are disposed to the outside surface of the first roller in an area that contacts the web.
 3. The sheet manufacturing apparatus according to claim 1, wherein: the surface roughness of the outside surface of the first roller is greater than or equal to 30 μm and less than or equal to 500 μm.
 4. The sheet manufacturing apparatus according to claim 1, wherein: the first roller has a channel formed to a depth greater than or equal to 30 μm and less than or equal to 500 μm in the outside surface in a direction intersecting a direction of rotation of the first roller.
 5. The sheet manufacturing apparatus according to claim 1, wherein: the asperities of the first miler are formed in a screen pattern.
 6. The sheet manufacturing apparatus according claim 1, wherein: the first roller has a round recess with a depth greater than or equal to 30 μm and less than or equal to 500 μm, and a width greater than or equal to 0.1 mm and less than or equal to 2 mm, in the outside surface.
 7. The sheet manufacturing apparatus according to claim 6, further comprising: a removal device that contacts an outside surface of the first roller, and removes material stuck to the outside surface of the first miler.
 8. The sheet manufacturing apparatus according to claim 1, wherein: the first seal contacts an outside surface of the first roller at an angle of greater than or equal to 45 degrees and less than or equal to 90 degrees to a virtual vertical plane tangent to an outside surface of the first miler.
 9. The sheet manufacturing apparatus according to claim 1, further comprising: a second roller positioned on upstream in the conveyance direction of the web from the first roller, and a second seal disposed to a second wall opposite a first wall of the first housing to contact the second roller, the second roller having asperities on its outside surface.
 10. The sheet manufacturing apparatus according to claim 1, wherein: the conveyor has a mesh member that conveys the web; the sheet manufacturing apparatus including a suction device configured to suction material including fiber onto the mesh member, and having a second housing defining the suction area; a third roller that is a third roller disposed to a position opposite the first roller with the mesh member therebetween, and has asperities on its outside surface; and a third seal disposed to the second housing to contact an outside surface of the third roller.
 11. A sheet manufacturing apparatus comprising: a drum with a plurality of holes; a housing covering the drum; a conveyor on which material including fiber that has passed through the holes accumulates as a web, and which conveys the accumulated web; a first roller that contacts a web conveyed by the conveyor; and a first seal that is a first seal disposed to a first wall of the housing to contact an outside surface of the first roller, and contacts an outside surface of the first roller at an angle of greater than or equal to 45 degrees and less than or equal to 90 degrees to a virtual vertical plane tangent to an outside surface of the first roller. 